Club 80-90 Forums

Put my AAZ in at the weekend, everything went fairly smoothly went for the big start up and nothing, starter worked fine before?

Now all i get is a slight clunk and the starter then smokes, engine turned fine on the crank when it was out, anyone have any ideas? Or will I just need a new starter?

Do you replace the fly wheel on the AAZ with the one from original engine ? If not the gears not match up.

Sounds possible that the starter motor is unable to turn the engine over - have you turned the engine over at all ? Hope its not ceased!

Ringo

Put Jx clutch and flywheel on, the engine turned fine when out of the van but now it'll only turn so far then "Stick" i've taken the starter off this mornind too to be sure it's not that thats jamming and it's still doing it

Is it possible that the bellhousing and engine haven't mated up right and the flywheel is getting caught on it? Not sure it's possible as the iput shaft and JX spigot bearing are so "tight" as it were that they couldn't possibly mate up without being in the right place?

I'm well and truely stumped (as you may tell im not mechanic)

Dubkopfeyellow wrote:
Is it possible that the bellhousing and engine haven't mated up right and the flywheel is getting caught on it? Not sure it's possible as the iput shaft and JX spigot bearing are so "tight" as it were that they couldn't possibly mate up without being in the right place?

I'm well and truely stumped (as you may tell im not mechanic)

Well, its a case of the blind leading the blind as far as im concerned then! I somehow doubt its possible to mess up the mating of the gearbox and engine because as you say - its rather tight.

Have you tried putting it in third gear and pushing it to see if the engine turns over ?

Im sure someone with more of a clue will come along soon....

Ringo

Thats what i'll try next, need to wait till I have a helper tho, as is usually the case with vans

Update your profile info so people know where you`re at! Maybe someone will have a look-see who knows what they`re looking at.

Have you tried winding the engine over with a socket via the bottom pulley crank bolt. Note it`s not easy with a diesel engine, but it should turn over. You can`t really get the gearbox and engine alignment wrong, BUT did you change the gearbox input shaft, or cut it down. I`m sure there is something about having to shorten the shaft when doing this conversion. Also spigot bearing has to be correct size etc.

Maybe loosen off the bell housing again and pry it away from the motor a bit and then try to wind it over with the socket on the crank again.

WATCH OUT FOR THE BOTTOM CRANK BOLT COMING UNDONE, IT`S A COMMON FAILING AND WILL WRECK THE ENGINE IF IT DOES !

Never heard anything about having to shorten the input shaft? Anyone elaborate on this

Tried to crank the engine today and it goes round to a point then stops, gonna take the engine away from the bellhousing later (or omorrow) to see for sure where the problem is as i'm sure it cranked fine when it was out

Spigot bearing is JX one (got the kit from Brickwerks) Kinda thought it would be very hard to get the gearbox lined up wrong as i'm sure theres only one way it'll fit in and bolt up

Thinking we've perhaps done something wrong between building the engine up and connecting it to the gearbox Or this input shaft thing could be the issue, if it does need shortening?

Crank pully seems fine nice and tight, no movement at all

juust a thought, did you change the cambelt? if so might not be lined up correctly causing the piston to contact the valves hence it only turning so far.

All the info on swap is on the Brickyard, what engine did you have originally? Petrol or diesel? It may be swap from petrol to diesel that requires the input shaft job. Not read up on it to much so not defo.

Could be the cambelt timing as stated earlier?

Ivorblueun wrote:juust a thought, did you change the cambelt? if so might not be lined up correctly causing the piston to contact the valves hence it only turning so far.

Interesting, was taking it in to have the cambelt done (engine has a warranty, and that requires that theres proof of a new cambelt, so was waiting to get it done properly)

Might be a case of getting a mobile mechanic to look at it or suck it up and have it taken to a garage!

Confirm that you used a Diesel gearbox input shaft if it was petrol gearbox before please - need to eliminate that asap!

Pretty sure its a diesel gearbox, we seperated the engine and gearbox again last noght to see if it was the gearbox causing issues and the engine still stuck after turning about 90 degrees

Reckon the crank is sticking, going into a garage tomorrow to find out for sure

Did you put a new oil pump on it?

No used exsisting pump, as it worked fine in the JX

Dubkopfeyellow wrote:No used exsisting pump, as it worked fine in the JX

Me and harrymann had a problem with a replacement JX pump on an AAZ fouling a con rod, it turned fine and then stopped dead.