Engine Rebuild

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Engine Rebuild

Postby Muppet » Fri Nov 09, 2012 7:57 pm

Right

Finally got my arse in gear and decided to get on with rebuilding the original van engine.
Managed to do a fairly good job on Rebuilding the crank nose and creating a much better flush surface.

So the jobs in progress

1. Block skim - evidence of head gasket damage
2. Block bore for 0.50 oversize pistons & hone - bore pitted from 12months outside and need new rings all round
3. Replacement head Skim - better that original head and needed another skim
4. Exhaust valve guide replacement - lot of lateral play in guides mainly exhaust guides
5. 1 piston ring set for O/S piston as Oil ring broken
6. Main Bearing set - water damage to main bearings
7. Crank mains Polished to remove water damage marks
8. Check Valve's and Cut to fit.
9. Drill and pin Crank Pulley with 2 silver steel pins

When I get this lot back.

1. Paint Block
2. Reassemble Head
3. Reassemble Block
4. Reassemble engine
5. Refit engine in middle of winter Lovely :shock:

What I still need

1. Head Gasket - 3 hole I suspect.
2. Full Gasket set 8mm Valves
3. Crank Seal Both ends
4. Auxiliary shaft Seal
5. Oil Pump - wear from Vac pump
6. Vac Pump - wear from Oil Pump


Will see how it goes
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Postby regcheeseman » Mon Nov 12, 2012 5:47 pm

What had you done to it? Very rare for a 1.9 motor to need a skim.

AND all the other work. :shock:

I'd lob a used full AAZ or 1Y short motor in and be done with it.

Never had a lot of joy with rebuilt plain bearing motors or stuff that needs a skim.

But good luck....
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Postby Muppet » Mon Nov 12, 2012 7:52 pm

regcheeseman wrote:What had you done to it? Very rare for a 1.9 motor to need a skim.

AND all the other work. :shock:

I'd lob a used full AAZ or 1Y short motor in and be done with it.

Never had a lot of joy with rebuilt plain bearing motors or stuff that needs a skim.

But good luck....


Well..........

Has been rebuilt some time before I got the van. VEGE head that had seen better days after
major contact on at least 3 occasions, 2 of mine.

Bores rusted & lipped form 180k & sitting in garden for 18months full of water :(
Groves/pitting on block around pre-combustion chambers wouldn't polish out.
currently running a Unknown Golf Lump can't read Engine code, runs but was only a temp fix.
been in 18 months never done anything to it other than filling it with oil when fitting.


Oh I might have to pop and see you about a Pump Rebuild, little more fueling/boost & possible
veg running.

Must admit this AAZ idea seemed a good idea at one point but I can't see the Technical differences,
main issue seems to have the same crank & Sprocket.
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Re: Engine Rebuild

Postby JOE » Mon Nov 12, 2012 8:46 pm

Muppet wrote:Right

Finally got my arse in gear and decided to get on with rebuilding the original van engine.
Managed to do a fairly good job on Rebuilding the crank nose and creating a much better flush surface.

So the jobs in progress

1. Block skim - evidence of head gasket damage
2. Block bore for 0.50 oversize pistons & hone - bore pitted from 12months outside and need new rings all round
3. Replacement head Skim - better that original head and needed another skim
4. Exhaust valve guide replacement - lot of lateral play in guides mainly exhaust guides
5. 1 piston ring set for O/S piston as Oil ring broken
6. Main Bearing set - water damage to main bearings
7. Crank mains Polished to remove water damage marks
8. Check Valve's and Cut to fit.
9. Drill and pin Crank Pulley with 2 silver steel pins

When I get this lot back.

1. Paint Block
2. Reassemble Head
3. Reassemble Block
4. Reassemble engine
5. Refit engine in middle of winter Lovely :shock:

What I still need

1. Head Gasket - 3 hole I suspect.
2. Full Gasket set 8mm Valves
3. Crank Seal Both ends
4. Auxiliary shaft Seal
5. Oil Pump - wear from Vac pump
6. Vac Pump - wear from Oil Pump


Will see how it goes




pics please
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Re: Engine Rebuild

Postby Muppet » Mon Nov 12, 2012 9:45 pm

JOE wrote:
pics please


Maybe :lol: :lol:

Will see what happens when I pick some bits up later this week
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Postby Muppet » Mon Nov 12, 2012 10:53 pm

lucky them bits is out the way
Done a bit of winter prep on Liz's winter wheels, re-spray in
Black'n'Shiney rather than stock-Steel Dullness.
couple of coats n lacquer = Shiney 8) 8)
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Postby regcheeseman » Wed Nov 14, 2012 12:50 pm

Oh I might have to pop and see you about a Pump Rebuild, little more fueling/boost & possible veg running.


Do it! I'm running on veg petrol mix at the moment and it's far superior to the veg diesel mix I ran before.

I'd sort the fittings out for a boost controller and maybe consider tapping the manifold for an EGT sensor before you fit it


To be honest, i'd see rebuilding the ABL? as throwing good money after bad, but that's your call.
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Postby Muppet » Sat Nov 24, 2012 9:33 pm

Woop!

Picked up engine bits Friday and got a chance to have a bit of a look at them today.

Well OMG I knew there was a bit of play in the barrels and pistons before they were replaced but much smoother fit now.

OK so far:-
Block skimmed.
Bored for 0.05 O/S Pistons.
Crank Polished & Pulley Pinned
Head skimmed
Valve guides replaced & valves ground, need a little manual grinding
new set of Main bearing & shims bought
Need to get block & Head Seals
Head Gasket & Bolts

Time for a bit of engine titivating to make it look pretty :shock: :shock:

pics to follow JOE
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Postby Muppet » Sun Nov 25, 2012 10:32 am

Block after a Skim & Bore
Image

looking a bit cleaner that before
Image

O/S Pistons
Image
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Postby mikey » Sun Nov 25, 2012 11:08 am

Looking good there all shiny, shame you can't see any of it when it's all back together. Hope your going to paint and polish the outside when rebuilt. 8)
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Postby Muppet » Sun Nov 25, 2012 2:59 pm

Thinking alike there,
Already in process of painting the block.
Think the compression is gonna be much better too!
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Postby Muppet » Sun Nov 25, 2012 7:44 pm

As i was saying
Image


Well it is a Red van :lol: :lol: :lol:
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Postby JOE » Sun Nov 25, 2012 8:08 pm

very nice mike looking good bud
:D :D
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Postby Globbits » Sun Nov 25, 2012 10:01 pm

Nicely done!
Taking cues from General Motors, you could call your new lump a "Red bottom"?
Or perhaps Red Arse
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Postby Muppet » Sun Nov 25, 2012 10:38 pm

Globbits wrote:Nicely done!
Taking cues from General Motors, you could call your new lump a "Red bottom"?
Or perhaps Red Arse


Thats lucky it could of so nearly been 'Baboons Butt'
:lol: :lol:

More updates as they arise,
Pictures paint a thousand words and save bloody typing :lol: :lol:
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