Engine overhaul

[DuaneEddy]

Wrong day to put the pistons in the oven - unless you let the turkey out!!

[kevtherev]

seems you need to prioritise things in your life better.
Christmas is once a year ...a camper is for life

[jeffj]

Was going to use the green scotch type pads to remove carbon deposits from gudgeon pins only. Pistons have just been degreased with petrol and did not intend to touch these.

Video does just show the pins being a gentle push in?

Pins now in freezer and will use hair dryer to warm piston through liner prior to fitting.

Or it is Monday - Wife will be out tonight - Oven will be free - Any residue burnt of liners might add flavour to the turkey tomorrow?

[DuaneEddy]

seems you need to prioritise things in your life better.
Christmas is once a year ...a camper is for life

[DuaneEddy]

The ring gaps need checking prior to putting on the pistons - most rings break due to insufficient gap.
Then as Sarran in video ensure they are the right way round - arrows pointing right direction - rings 120 Deg apart - light oiling and don't force!

[jeffj]

Have now got the pistons fitted into liners. Garage is cold and liners very cold to the touch so have brought inside the house and placed on radiators to warm up.



First two valves fitted.





Heads completed.



Pistons inserted into the liners.




Have wrapped liners/pistons and placed on bedroom radiator to warm up. Pins in freezer.

Worked out the small tube of sealer must be for under the clyinder head nuts.

Was reading MM engine build this morning and sure he mentioned cleaning pins. How did you clean them? Very good thread and a lot of help. Also following your sunnivagon thread as I will have similar work to complete on a 79 bay once this engine running again.

Sorry to Sarran but have not had chance to sort out new photo account yet. Hopefully these pictures are a better size to few. Enjoyed your video link and found informative. Is part 2 available?

Just tried one of the pins from the freezer into the connecting rod and it slid straight in. Hopefully with warm pistons this solves my problem.

[Plasticman]

you could have gone to the plumbers places and bought a can of freezer(handy to keep in for warm beer too)
mm

[jeffj]

Just tried pin in one of the warmed up pistons went straight in, but got stuck coming out and had to remove with threaded rod. Looks like its going to be a one chance fit.

Going to leave both for a couple of hours and go for it after tea.

[jeffj]

Right. Some success. First Liner installed on right bank, wrist pin inserted with a lot of fiddling. Circlip even worse. As MM said you will always drop the circlip. Found it and got it fitted.


My daughter was helping me so set up system as follows.

Daughter collects No 3 liner/piston (left hand bank) from radiator in house. While I fit black O ring she returns to get No. 5 pin from freezer. (no 5 because I bagged it up with valves & springs) Me ready with piston in position she returns with pin. Out of bag into piston and fiddle to get it to run into con rod and home. Done. Spend 20 minutes getting circlip in.

Right now get me No 4 liner/piston of radiator and No 7 pin from freezer. Liner arrived and prepped ready. Daughter arrives with No 5 pin????????? What happened?? She blamed me saying I asked for top bag but No. 7? So she brought me the second bag?

What do I do? Use no 5 pin with wrong piston?? Decide to leave this side and move on to Right hand bank.

Repeat process for left hand bank and all goes okay.


Fitted green O rings to top of liners.


Placed skim of sealing compound in channel of rubber seal, fitted seal then skim of sealer on top.

Placed steel gaskets in head and retained with grease. Fitted push rod tubes and fitted head. Torqued heads down.



Fitted push rods & rocker. That is one side finished. Temp fitted rocker cover until I set valve clearences.


That will do for today. Will not get chance to do anything else now until Thurs due to xmas day and football on Wed.

Merry Xmas to everyone.

[billy739]

did you fit new exhaust valves?

personally i would haver fitted big end shells also as its common on topend rebuild motors to blow the bottom end.

[jeffj]

Reused exhaust valves. All looked okay on inspection. Also reground and had a nice matt finish to profile.

Engine was a good runner before strip down. Only reason for the strip down was the pressurisation of the cooler system. Confident I found the leak causing this on no 1 cylinder. (rear left hand bank)

[jeffj]

Back in garage this morning with an early start.

Removed No 3 liner, pin and piston to fit correct pin.

Both liners & pins fitted plus gaskets ready for head. Hands to shaky this morning to take decent photos? Wonder why?


Head fitted and torqued down.


Push rods and rockers fitted.


One engine. Still have to set valve clearences so fitted old covers temp for moment.

During build up followed all the normal tips and a few others that have kindly been passed on.
Kept turning engine over after each operation to make sure nothing binds.
Keep everything cleaned and numbered. Correct use of equipment like house rad for warming liners/pistons, hair dryer for warming end of conrod, freezer for cooling gudgeon pins.

Now need to build up misc items. Distributer, water pump, fit new oil seals front and back, new oil pump, clutch.
Also all tinware and pipes and cross members to clean and paint.
One small welding repair on exhaust.

Things not to forget.
2 studs to drill out for tin shield under engine.
Change oilite bush.
Check out starter motor.
Ooh - Pin and spring that fell out for fuel pump?

Thats it for today. Now off to see Boro v Blackburn.

[jeffj]

Drilled out two sheared studs for pushrod tube guard. Also need to do a small weld repair to one of the guards as it is corroded through.

Removed engine from stand and onto bench so I could refit flywheel. Could then remove crankshaft pully for fitting of new seal and oil pump.

Started with removing old seal, cleaning down area, greasing and fitting new seal.

Then moved onto oil pump. Removed 4 nuts and cover. Face of pump cover worn so cleaned up with wet and dry.


This is cover after wet and dry treatment. Scores on face still quite deep so will order new cover tomorrow.
Also will order four new nuts. Did not know that these must be renewed. Nuts special with built in seal. You would think these would be supplied with new pumps?


Old oil pump with cover removed.

Will remove oil pump tomorrow. Have soaked with plus gas overnight. Might have to make up puller to remove it, but cannot see the supposed thread in the pump housing?

[jeffj]

New oil pump installation.

New oil pump cover. Cleaned face flat with wet and dry.


Cover as delivered with coat of paint.


Wet & Dry after 15 minutes


Wet & dry further 15 minutes


Wet & dry complete further 10 minutes


New cover against old.

One of the studs came out on removal so removed the other three. This allowed me to rotate the pump to work it free.


Pump removed and studs installed.


Inner gasket fitted.


Pump fitted.


Outer gasket fitted and pump greased up.


Oil pump cover plate and crankshaft pully fitted.

[jeffj]

Water pump fitted.


Water pipe.


Rear crank shaft seal removed. Retaining ring damaged so purchased second hand item from The Engine Shop.

Replaced flywheel to check end float. 0.08mm which is within spec.

Taped over area and placed engine back on stand.