Assembly

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Oversize piston rebuild and E85 conversion
Rebuild the worn bottom end with 81.5mm pistons, revise the fuel system for E85 and improve transmission alignment and shifter support.
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Plan
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Parts
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Gallery
Decisions & Unknowns
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Bore the scratched cylinders to 81.5mm and use Wiseco pistons with matching 139.5mm rods. Return to NA cams.
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Correct the adapter's loose centering lip and revise the Tilton contact geometry rather than retain the scraping release bearing setup.
Tasks
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Machine the block and assemble with and fresh main and rod bearings.
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Install and replace the old fuel hoses with ethanol-rated Aeroquip 2556 hose. Fit a fuel filter and GM ethanol sensor in the factory pump carrier.
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Machine a revised transmission adapter, change the Tilton piston and bearing, and fit UUC mounts with support cups.
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Modify an E28 shifter bracket with Delrin bushings and a tunnel-mounted E46 M3 rubber mount. Replace the selector joint.
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Replace the cracked radiator with a Nissens 1992 940 NA radiator and reinstall the engine.