Several months ago, we placed an order at Purifoy Chevrolet for a ZZ4crate engine (GM
PN 24502609).
When it comes to an automotive project, you know you're nearing thoseall-important final steps when you begin to worry about the engine. Thismonth, Team VETTE focuses on preparing our future powerhouse--a GM-issuedZZ4 crate motor--for installation. This popular small-block is availablefrom any GM parts dealer; we ordered ours from Purifoy Chevrolet.
Unhappy with the idea of dropping an anemic L98 intake onto our350-plus-horsepower crate engine, we'll be taking this opportunity toupgrade to an ACCEL Super Ram. While this John Lingenfelter-designedpiece is hardly cheap, its benefits are reported to be well worth theprice tag. While we're at it, we'll also be adding one of Proform'sGM-licensed electric water pumps to improve cooling and add a few extrahorsepower.
In future installments we'll cover the items excluded this round, suchas the location of the oil-pressure-sending unit. More involved jobs,including sensor placement and the exact details of the ACCELinstallation, will get their own articles. Until then, here's a quicklook at what we've got going on under--er, outside of--the hood...
It's always a good idea to give your new engine a once-over--especiallyif it's been in the hands of others. Here, a timing-chain-cover bolt hashad its head ground off to fit the later-style water pump. While thissolution will "work" if you never plan to remove the cover, a bettersolution would have been to change the pulley to a deeper-dish style toclear the bolt. | 
Meanwhile, this fuel-pump block-off plate was installed with mismatchedhardware and no gasket. | 
The Corvette's reused sensors also needed some work. If you've justspent a few thousand dollars on an engine, don't chinch out on detailslike these. |
Finally, our inspection revealed that the dipstick chute wasn't securelyinstalled from the factory. We fixed it by resealing with some RTV. | 
Our next step was checking for top dead center (TDC). While it appearedto have been marked by the factory, it only takes a moment todouble-check. | 
First, we removed the spark plugs to allow the air in the upper assemblyto move more easily. |
Next, we turned the crank, having a second pair of eyes check the No. 1exhaust port for TDC. | 
Next came the oil-filter adapter. Our unassembled crate engine arrivedwithout this important piece--a problem remedied with a call to GMPerformance Parts. | 
For the filter stud, you'll need GM PN 03952301. The oil-pump primer--apiece you'll need further down the road--carries PN 12368084. |
With a little red thread lock, we secured the bolts into the block. Ifyou want to use new, official GM parts, these bolts are under PN3951644. | 
With everything secured, the filter boss should look like this. | 
It's inarguable: The stock L98 intake sucked--or rather, didn't suckenough. Recognizing this, we decided to upgrade to one of ACCEL's highlyregarded Super Ram units. Just how good is the Super Ram? We're not sureyet, but we'll let you know soon, when we cover its installation. |
With the carbureted ZZ4 manifold off the crate engine, we got a goodview of the top end. After carefully scraping off the gasket residue, weprepped the motor for the new intake. | 
For the step next step, we needed this GM PN 10147994 gasket kit... | 
...as well as this ARP intake-bolt kit (ARP PN 135-2002). Check ARP's Website for more styles and availability. |
Armed with manifold-torquing instructions, we bolted down the top. | 
Setting aside our previously discovered "issues" for the moment, wedecided to upgrade to a Proform electric water pump. | 
Capable of flowing 35 gallons per minute, the new pump should have noproblems keeping our ZZ4 cool. And with less belt drag, output should beboosted as well. |
Following the instructions, we installed our new Proform pump on theblock. While hardware is included with the pump, we chose to use theextra four bolts inside the ARP kit for uniformity. | 
And there you have it. While there is still the matter of the frontbracket assembly, we've decided to tackle that project after finalinstallation. | 
Next we gave our engine's internals a quick "wash." Using Pure Power'sbrand of oil, we opened up the drain plug and flushed out the assemblylube that came in the crate engine. |
This is the sort of stuff we drained out in the process. While itshouldn't harm your engine, it also doesn't do it any harm to get rid ofit. | 
This step was followed by the installation of another of one of PurePower's oil filters. With engine break-in just over the hill, we wantedsomething with a little more filtration capability than a cheapconventional filter. | |