Join Date: May 2009
Location: Texas Hill Country
You might want to start from scratch. Lay the crank in place and plasti-gage the thrust bearing. If all looks good, clean up the journal and torque that cap down and check rotation. If it spins freely with the thrust cap torqued down, repeat the process for each main cap, checking rotation every time.
If you make it that far with no rotation issues, start installing piston/rods. Make certain that the expander ring is butted together and NOT overlapping. Make sure that the piston slides right into the bore with no fuss. If you have to finagle it, it's possible to roll a thin oil ring right over and that's no good. Plasti-gage the rod bearing. If that goes well, clean up and oil the journal and torque the rod cap. Check rotation. Repeat.
If you check rotation after each step, you'll know right where your problem is.
It's also quite common for bearings to be all over the place as far as actual clearance goes. You may have to plasti-gage all of the journals and see if you need to shuffle the shells around a little.
Also, spray a paper towel with a shot of WD-40 and wipe each cylinder. If the towel comes out with anything on it, that bore needs to be cleaned a little better.
Hope that helps!
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