I pulled a OBDI 1.6L 16V from my 4-door, and am thinking about sticking it into a Samurai. Mileage unknown (not original motor). If I do, how do I check this thing out while it's pulled out? I can maybe short a 12v supply to the starter - can I do a compression test when it's cold? Is there a way to check the rings, valves, timing belt etc while it's pulled (and easier to work on). It may get a turbo (depends on how I like the power after it's installed), do i need to re-ring it, or will a compression test be fine? What would you do?

It would have been easier to do a compression test while it was still in the vehicle, but you can still do it on an engine stand. A leak down test is a much better indicator of overall condition of your engine though, so if your gonna do it, I'd go that way. If you do do the compression test cold you'll probably get low readings. A good number to look for in a compression test of the 16v is 188 or better, and all cylinders within 2/3lbs, with a warmed up engine.

I've heard of some kinda "plasti gauge" that's supposed to be able to tell if parts are within tolerance - I think it was for things like main barrings Anyone know anything about this method?

Yes plasti gauge is for measuring main and rod bearing clearances!

Yes plasti gauge is for measuring main and rod bearing clearances!

Yup, the plastigauge is placed across the bearing and the cap is tightened to spec,  then you take the cap off and compare the squished plastigauge to the chart on the package, whichever line its closest to is the measurement.  Its used to measure where a micrometer, caliper, or feeler gauge won't fit.

So, it's like a squishy shim that retains it's shape after being squished... and that determines if something is "too loose" or "too tight"? Is a leak down the only way to test the rings? I have a compression tester, but no leak down tester 

So, it's like a squishy shim that retains it's shape after being squished

It's a plastic string (looks kinda like fishing line) I think they come in different color/thickness for different tolerance ranges. It stays flat after you torque the bearing down, like a penny on a train track. I'm not sure but I think you can use your compression tester to check leakdown,  I'll ask my boss tomorrow if I don't forget, I got a bad memory.  

Well I asked my boss if leakdown can be checked with a compression gauge,  he said no-go

Cheap leakdown tester from HF:

http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=94190

Guess that means I need to get my hands on a compressor too.

Yeah,  sorry I'm a little spoiled from workin at a auto shop for so long, I gotta remember not everyones got one.  If you don't wanna have to buy one you could rent for pretty cheap I think.