1.9 aaz engine rebuild

[Funbus]

Weh hey!! I've bought my lid.



I think if I paint the van orange that you won't even notice that ratchet strap!
I'm gonna start a new thread for bodywork as I'm not sure of the best way to fix it on.

[Funbus]

Well, I've had a good couple of days on the van. The engine is coming along nicely.

Measured everything and its all good, within tolerance. I didn't want the added chew of regrinds and rebores etc.

I replaced the knackered piston with brand new kolbenschmidt replacement



And I've cleaned the existing 3 up and replaced the rings. Found that a wire scourer and elbow grease was the only way. I used an old ring to clean the grooves.



Removed the oil jets, which were a bugger to get out, and checked them over. I also gave them a good clean. Just held them in cleaning fluid and depressed the ball bearing in and out.



I was having a nightmare fitting the oil jets using the original torque bolts. The heads started rounding out and I could not get them to 27nm. I feared stripping the threads in the block so I abandoned them. Hawk fasteners in middlesbrough done me the same size bolts, in high tensile steel with 4mm Allen heads. Still couldn't get them to required torque so I added a bit of lock tight and lowered the torque slightly.



Anyway, they are fitted now along with new main shell bearings. Had a nightmare with getting the bolts to secure these. Brickwerks again proved invaluable and promptly located some of the correct 65mm bolts.



Crankshaft is back in with new oil seals on both ends. Pistons back in with new big end bearings and stretch bolts. Painted the block with high temp paint from halfords.



This rebuild is coming along nicely. It all turns by hand, nice and tight with no rubbing, grinding etc. doesn't look to shabby either!

[ELVIS]

Well, I've had a good couple of days on the van. The engine is coming along nicely.

Measured everything and its all good, within tolerance. I didn't want the added chew of regrinds and rebores etc.

I replaced the knackered piston with brand new kolbenschmidt replacement

Think I mentioned it a few weeks back chap. That deffo looks like witness marks from previous valve/piston contact. Have you had Dti on the head to check valve guides (especially on that cylinder) are all good?

Loving the build thread chap

[Funbus]

Cheers Elvis. Valves all ok. Guides ok. Physical check showed that they are sliding in and out like a slidey thing!
Only thing not measured was conrod but I put a good eye over it and gave it a good coat of looking at! I think it's all fine.
The marks on the old piston barely touched the surface. They have cleared nice circular patches of carbon though.
Ill be ordering my head gasket, bolts and timing belt kit later today.

[Funbus]

2 become 1. Cylinder head back on along with flywheel and clutch.



It was good fun getting the head bolts torqued up by my self. I'm only a slender fellow but just managed to hold it still. I went for a 2 notch head gasket - it did have a one notch fitted. As was pointed out, the valves were very close to the pistons, even removing the carbon! I've used new bolts on flywheel and crankshaft pulley.

I've started on the bodywork now so the engine is moving on at slightly slower pace, allthough I never did manage to get out of first gear.

What is the though on refitting the engine? I've got the gearbox out. Should I put them back in individually or fit the gearbox to the engine and refit the whole lump as a oner?

[Funbus]

Gearbox is out. I thought I'd remove the bracket, de rust and paint the area before putting the gearbox back in. Good idea then snap! snap! 2 of the bolts sheared off



I had an hour spare today so thought I'd sort this out. Plenty of penetrating oil and drilled some pilot holes, tried with the easy outs but no joy. I had to drill the bolts out and re tap them. Not the easiest job to do without jacking van up, and on the drive. Then the white stuff started falling!!



Anyway, I've got the job done. Just need to buy some new bolts - stainless!

[max and caddy]

Missed this thread so far...with regard to the melted piston it's very likely caused by a bad injector...also the valve contact was most likely caused by the cam timing being out a little...is the crank pulley perfect..? it needs to be or it will give you grief in future.

The oil spray nozzles...there is 2 sizes of bolt on those and I suspect you have been trying to get the small ones done up to the big ones values....lucky you didn't snap the bolts off!

Other than all looks well now but I would advise new tappets if the engine has been running with the valves hitting the crowns as they are very brittle and can develop cracks leading to the tops coming off in future...if you decide to change them only use INA ones...I learnt this the hard way recently and no surprises the Chinese option is utter turd.

Maybe a bit late now but if you can get away with a 1 hole gasket use it...the closer the piston gets to head the better the economy and power will be...if its to late don't fret about it but I assure you the closer the better.

New rings? Have you honed the block?

[Funbus]

Hi, thanks for comments.

Crank pulley is sweet, refitted with new bolt of course.
Block was honed prior to new pistons going in.
I suspected faulty injector or pump timing out for the melted piston. I'm getting the injectors re conned with new nozzles - been quoted £160 for all 4. Does this sound about right?
I've already fitted 2 notch gasket. Wanted to make sure, especially after going over the surfaces with emery cloth.
Sounds like I've been lucky with the jet bolts. Phew! That would have been a nightmare.
Just in process of fitting gearbox so I can do all the timing then back in to the van she will go.

I also need to figure out what I'm doing with turbo oil return. Maybe making an adapter to go between sump and oil filler pipe?? Any ideas. Would like the brickwerks adapter but summers nearly here and I need to put money into the rest of the van.

[max and caddy]

Sump would be best done summat like right...maybe get a weld on fitting and...er..weld it on in the standard ish place?

Pump timing would do the same damage to all the pistons so its either an injector fault or may be has been chucking oil into one pot...most likely an injector...had one like that, wore out the rings on one piston.

£160 is ok if the nozzles are decent and the pressures are set properly...if they are just bunging some cheapo nozzles on you may as well do your own.

[Funbus]

Any recommendations for somewhere to get the injectors done?

[Funbus]

This is the only code I can find on the gearbox



Is this the correct 5 speed box for my AAZ?
Cheers.

[max and caddy]

Any recommendations for somewhere to get the injectors done?

Diesel bob...google him.

[Abyss]

Any recommendations for somewhere to get the injectors done?

Diesel bob...google him.

I will second bob for the pump as well, he can reseal with viton seals so you can run vege oil in the future.

The 3H box will be OK, know a few people with AAZ and 3H that have been running fine for a while

Nozzles on injectors, I have used https://www.uniteddiesel.co.uk/" onclick="window.open(this.href);return false; with great results. They can also do nozzle upgrades for more power!

You running an oil cooler up front with this setup? Plenty seem to need to do it on these lumps as the oil temps can get a bit high.

[Funbus]

Cheers for replies. I've contacted diesel bob and a local company and both are same price ish. I'll decide next week which one.

Glad the gearbox will be ok. New drive seals and bolts and she'll be going back in.

I might have to get pump done at a later stage. Get a bit of use out of her first.

This van doesn't have oil cooler up front. Not sure whete to start fitting one. I'll have to see how she runs in summer.

[Funbus]

I've not done much with engine lately. I've been making the most of decent weather and sorting bodywork.

I have had injectors done



Used a local company - flavells in stockton.



I've got them back in now, along with fuel pump and new timing belt.

I'm going to get the turbo reconditioned as its abit worn.
Any body used midland turbo? They seemed switched on over the phone and a decent price to!