1.6 jx Td rebuild

[Rascal]

I recently collected a second hand short block from a member with the intention of a full rebuild and then swap for my current JX that runs very well albeit a bit oil thirsty..
So started the strip down

Hmmm 77.48 that's the second size overbore



Looks like the crank has previously been balanced

So the plan is to get it to my local machine shop bores checked cleaned up etc.. Then go from there. I can see brickworks sell the second size piston rings. 77.5 but not the pistons..(obviously I already have these.)
So the question is if the Bores are OK do I just get the pistons cleaned up and refitted with new rings. Or am I waisting my time and money with this block?


Is the green paint normal? Im Sure I read somwhere this indicates millitatry?? It's from a doka according to the member I got it from

[Dueller]

When i had my Doka i had this option to rebuild too and modify etc etc, went the engine conversion route instead to a more modern engine

If i had to do it again id strip a Passat/Audi down for the box and engine, Tim Shettle has all the bits you need etc for an AHU or a PD fitment

Fit a standard engine and never mind the number chasers or modders

For me its about cost vs longevity and enjoyment

My current Caravelle has a 1.9DG i rebuilt and ive a Ford St170 swap planned, just need the flywheel to torque converter sorting out as its taking a few brain cells...

 

[Rascal]

Well my spare block came back from the machine shop with the all clear as did the Head. So I'll just rebuild with fresh rings and turbo rebuild... Then swap out the current engine.. Not interested in TDI and a gearbox rebuild and not chasing bhp. I actually like the Jx as its a good reliable engine as far as iv experienced and I like it's simplicity and non reliance on ecu's and electronics currently I'm getting 28-30 mpg in a westy so can't argue with that and I'll finish the veg oil conversion. My L200 has been running on veg for 7 years now..
Iv seen the yanks fit zetec in their vanagons and iv a 1.8 zetec on twin 40s in my 105e.. What ecu are you going to run on the st170 and are you going to keep the vvt?

[Cecil]

I am curious about what appears to be an indent in the tops of your pistons where one of the valves looks to have been contacting it.is that so?
My jx block is green . I bought my van (first registered in Germany)from a German owner living in Spain,he also owned a Doka . Quite possible the engine in my van came from the doka .Dont know if any of that gives any clues as to why it is green .

picture of my engine.

[Rascal]

The pistons have indents as you refer to them in the Crown (top of the piston) to aid in mixing of the air and fuel.. Also the larger round marks are just carbon build up around the exhaust valves.. The Jx is an interference engine.. Which means that if the timing is out the valves will hit the piston and bend them and will not turn over etc..
That is not the case with mine it turnt over freely and had good compression

[mrhutch]

I am curious about what appears to be an indent in the tops of your pistons where one of the valves looks to have been contacting it.is that so?

To be fair I thought the same..  Having rebuilt a few diesels I have never seen carbon deposits like that, does look like the exhaust valve has kissed the piston top.  

[Rascal]

So having removed the pistons. They have indeed been hit by the exhaust valves. I can only assume that previously cambelt has snapped and the head has been replaced.. As engine ran previously and head passed compression test...