Daniel5691

Hi !

I am finally beginning the fabrication and assembly phase of my 5.0L Hybrid engine.

As a utter n00b, who is prone to accidents, bad luck, and poorly-reasoned choices, I've decided to consolidate my assembly project into one thread if possible. Maybe at some point, others can use the collected wisdom to pursue the same project.
I did read through the other available hybrid-build-threads, like Ducman's awesome project, and found that most of you guys are waaaay past my pay grade when it comes to "assumed level of knowledge".

So I know most of my concerns will seem stupidly simple in a lot of cases. For instance, my first task involves prepping the 5.0L short block assembly for eventual mating with my rebuilt 4.7 EuroS heads.

I know that the machine shop needs to "relief cut/ fly cut" the pistons. I am taking a couple of the original old 4.7L EuroS pistons to provide a comparison for them. They will also have the rebuilt heads to measure and examine for clearances.

Q1: are there any other "HYBRID-SPECIFIC" tasks that the machine shop needs to address before assembly?
They are already going to inspect bearings, bores, etc,... all the "typical" short block rebuild issues.

Q2: New piston rings will be installed. What is the correct "prep" for the Alusil cylinder bores for new ring installation?
I know some 928 blocks have been damaged by standard/typical cylinder honing methods.

Q3: What are the dimensional/mating external differences that need to be addressed prior to assembly and installation in the car?
For example...
Do I use my "old" style motor mounts, or the type used by the 5.0L short block?
Different heat shields?
Do I use my old 4.7 water bridge?
What about mounting locations for the alternator, pulleys?
Do I still use the 4.7 parts on the 5.0L block?
Will my (nearly-brand-new) 4.7 water pump work on the 5.0L block?
Which harmonic balancer do I use? 5.0L or original 4.7 EuroS?
I apologize. I warned you these questions would be very fundamental LOL.

Anyway, I simply can't thank you guys enough for your patience and expertise.
This poor old 928 would have been E-bayed months ago without the amazing help here at RL.
Thank you +928 +928 +928.......

Dan

mark kibort

use everything on the 4.7 and bolt it to the 5 liter block. there is only one small difference in mounting the alternator, that requires a very small mod.. forgot what it was though.

what pistons out of the 4.7 are you using as a template? make sure if its the 80-83 (deep cuts) they dont try and cut the reliefs that deep. only use .175".. write that down... .175"

see my build thread on the details. ive done it a few times!

mark kibort

what 4.7 motor are you mating to the 5 liter.

dont forget to cut the valve reliefs so that you are able to optmize the rod angles on the 5 liter pistons installation. in otherwords, you make a left side and a right side set of pistons with optmimal rod angles. this was Greg Brown's advice that is beter for the motor, and might provide an additional 10hp.

whats the engine managment system. euro LH, euro CIS? US Ljet?

Daniel5691

Thanks for the details Mark. I'll be sure to include those remarks to the machinist.
I'm using Bell Motor Service in Louisville for the short block work. They come well-recommended by some of the local european-car guys and they are very detail-oriented.

My 4.7 was originally a 1981 S model, M28.11 designation, and I will be using the original stock Bosch CIS/K Jet mechanical injection system from the 1981 EuroS 4.7. Again, thanks.

mark kibort

great match up. should be a superpowerful monster! thats the last one i built.
it made 315rwhp

Daniel5691

Next dumb question:

Do I use head gaskets originally intended for the 4.7L engine, or
a different set for the 5.0L S3 short block assembly?

Again, this thread is my safety net. And i can be pretty dangerous with hand tools and undamaged parts...

Dan

Ducman82

S3 . Correct bore size

Daniel5691

Thank you sir.

Daniel5691

Just a fun photo of Bell Motor in Louisville.
The shop is owned by Tom Bell, and was founded by his grandfather way back in the 1930's.
I picked up an amazing 5.0 short block from Fred here on RL (FBIII) and it's well on the way.
Thanks.

hlee96

Bump for any updates? Please?

Daniel5691

Hello Hoi !
Thanks for the bump !
I have made some further progress on the 928S.
I had my cam gears coated and received them back recently, they look amazing.
The block and piston work is scooting right along, I should have the lump back in roughly
2-3 weeks.
I am really trying to make this a monster WYAIT project for the engine bay at the same time,
as well. That has taken some extra time as I have needed to save the funds to buy all the shiny things ha ha.
How are your projects coming?
Did you get your 5.0/S hybrid back together ?

hlee96

I just scored an euro s CIS top end from Arizona and having the parts send to dr greg brown for a hybrid built with my 5l bottom end. Hopefully, it will arrive about the same as as either my '84 parts car turned driver or my '78 is ready for the "insertion"'. Decisions, decisions, decisions.