Club G40 Forum
Club G40 => Photos and videos => Topic started by: Boris on May 15, 2011, 08:04:41 pm
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Hi everyone, joined the forum recently. Heres the G40 I bought as a non runner:
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/208398_1931519121026_1033688202_32340559_8281319_n.jpg)
Has low compression on cylinders one and four, which I was sure was down to an incorrectly fitted head gasket. The cylinder head had been done just before I bought the car. So I got to work replacing it:
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/221898_1942342591606_1033688202_32356878_1182071_n.jpg)
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/217311_1942342831612_1033688202_32356879_5958832_n.jpg)
(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/221758_1942343031617_1033688202_32356880_3710339_n.jpg)
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/222950_1942342351600_1033688202_32356876_2437894_n.jpg)
G-lader was looking a bit beat up
(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/222379_1946223688631_1033688202_32364972_6604251_n.jpg)
So gave it a wee spruce up
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/217295_1946223368623_1033688202_32364970_7896037_n.jpg)
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/222423_1946223888636_1033688202_32364973_4764599_n.jpg)
Removed head
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/215432_1954580417544_1033688202_32377407_8271267_n.jpg)
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/227017_1954580577548_1033688202_32377408_3993269_n.jpg)
As you can see, lots of action on cylinders two and three, not so much on cylinders one and four.
So I've replaced the head gasket (thought I'd taken a photo of the two of them together, but doesn't seem to have saved. Oh well)
Head back on and camshaft refitted
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/224379_1954580657550_1033688202_32377409_5170867_n.jpg)
Mostly rebuilt.
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/227187_1954607898231_1033688202_32377502_3925663_n.jpg)
As it turns out, the problem persisted.
Did a pressure test yesterday:
Before:
Cyl 1: 6 bar
Cyl 2: 13
Cyl 3: 12
Cyl 4: 9
After adding some oil to cyl's 1 and 4:
Cyl 1: 9
Cyl 2: 13
Cyl 3: 12
Cyl 4: 11
Confirmed what I suspected in that the cylinder rings are knackered. Also, listening to the engine, it seems the big end bearings may also be damaged.
Luckily, I managed to source a replacement bottom end from cheddarcheese on here. So stripped the engine again today, this time down to the bare block ready for the swapover. Just waiting for the block to arrive which should be on Tues.
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Charger looks nice. Were did you get that green screen wash from?
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I'm not sure about how the charger turned out, a little too bling for my liking, will probably redo it a more suble shade or strip the paint off it and polish it.
Don't know where the screen wash is from to be honest, it was in when I bought the car. :D
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looks like halfords screen wash that. Ive got some in mine. Whilst i had it off the car it had been leaking in the garage. It looked like i had a wounded predator in there ;D
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[Arnie]If it bleeds, we can kill it[/Arnie] :D
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How do you get an engine onto a stand without a hoist? Bodge it of course
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/231036_2004817713445_1033688202_32442340_7739378_n.jpg)
Finally got there though after using another two sets of ladders and another baton to lift the other side. Left me with this:
(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/229221_2004819433488_1033688202_32442343_4020921_n.jpg)
Some gunking and a coat of paint later:
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/226900_2004819193482_1033688202_32442342_5998521_n.jpg)
So now its ready to be fitted next week if all goes to plan.
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:) ;D :D ;)
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:) ;D :D ;)
Theres something hidden by the oil filter that I'll post up later ;)
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Day 1 of the engine swapover:
(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/254489_2021666414652_1033688202_32460615_2692265_n.jpg)
Out with the old
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/253539_2021666654658_1033688202_32460616_1057282_n.jpg)
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/252664_2021666814662_1033688202_32460617_8272916_n.jpg)
In with the new
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/247739_2021667054668_1033688202_32460618_1638867_n.jpg)
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/254209_2021666174646_1033688202_32460614_6657685_n.jpg)
Finishing the rebuild tomorrow and hopefully starting it up.
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;D ;D
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Had to be done ;D ;)
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Well rebuilt the engine today (didn't bother taking any photo's, cos you've seen it already. Anyway, all went to plan, checked the compression with the new bottom end and three cylinders are at 12 bar, one at 11, so that worked out perfect.
However, when I start it up, its as if its only running on three cylinders. Revs ok, but wont hold idle and runs rough. Checked everything, including the timing in case i'd missed a connection or vacuum hose somewhere, but all seems in order. Now I'm thinking ive a dodgy spark plug somewhere or an injector blockage. Thoughts?
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are you positive the plugs are in the right order?
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yes mate check your plugs are in order. iv had the same problem or check all your electrical connections are the pluged the right way round!
i had the white throttle plugged in the wrong way once witch took me ages to realise.
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You mean the actual physical plugs? I have the ht's going 1342
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from 9 o clock on the dizzy? anti-clockwise?
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Yep
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Actually, nope. Double checked and found they were going clockwise. d'oh.
Once that was sorted, I fired her up and she idles. However, still seems to be hesitating and I'm not getting full power. Wondering if the timing needs properly adjusted, but is there anything else likely to cause this i.e. plugs, ht's etc... (I have a new set of ht's on the way)
Cheers.
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i'd say its the dizzy timing needs adjusting.
and- i'd laugh at the leads thing, but we've all done it
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I did try advancing it and retarding it very very slightly, but didn't seem to make much difference. Is that likely to be more than a few mm out?
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get a timing gun on it to do it properly!
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Yeah, I am, was just wondering in case anything else was wrong. Cheers.
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Reason it wasn't making a difference was that I'd forgotten to unplug the blue temp sensor. Timing is now spot on after borrowing my mate's timing gun. Still misfiring though due to a faulty spark plug (replaced the ht's with double silicon ones).
New spark plugs arrived today though, NGK BP7EVX ones, so should have the car running properly this weekend. Is it not saturday yet? ;D
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Almost there dude!
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I know, I'm choking on driving it ;D
Need to get the merc sold first and that's got a few repairs needing done too. Probs be next month before the polo's back on the road. Then I've got alloys to buy, more lows, pulleys, induction etc, etc.. It'll be an ongoing project for a while I think.
Gonna give it an oil and filter change this weekend too.
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After fitting new spark plugs, the car is now running sweet as a nut. ;D
Anyone want to buy a merc? ;)
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Finally got the car on the road tonight after fitting a new hub. Snapped a bolt in the old one and couldn't drill it out.
First time I've had a proper drive of the car as it was bought as a non runner. Wasn't giving it full throttle as I want to put a few miles on the rebuilt engine first but damn these wee cars are fast. :D
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congrats :) enjoy the run in period because when you get to open it up after, you'll be grinning from ear to ear!
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Well, that was short lived.
Whilst trying to run the engine in, I've made a stupid mistake by topping up the oil with what I thought was the right grade, but which didn't mix for some reason.
Result is I think I've cooked my engine. Managed to get the car home, but was losing power and the engine was getting progressively more noisy. Went to start it up the following morning, and loads of white smoke tell me the head gasket's gone.
I replaced the gasket with a used one I had in the garage also using used head bolts (both used only once previously). Obviously, I know they're supposed to be replaced with new items, but couldn't get hold of them at the weekend. Started the car and still blowing white smoke.
Questions:
1. Is the head likely to be warped, which caused the head gasket failure. The gasket which was removed had no obvious damage, i.e. blowthrough etc...
2. Will a skim and new gasket / bolts replacement be likely to fix this?
3. Do you think using new head gasket and bolts will suffice without the skim?
Thanks.
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Decided to hold off on the head skimming and change the gasket only. If I still get the dreaded white smoke, then it'll definately need skimming. Hopefully it won't come to that. Fitting it tonight.
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Yep, white smoke again, head is definately warped. >:(
On the hunt for a local company to skim it now.
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ok. Had head skimmed, changed head gasket, refitted. Was still not running right (misfiring) and blowing smoke.
Got new w5dpo spark plugs and fitted them. No longer misfiring, but still blowing smoke (blueish white). Set timing with timing gun, no difference.
There is a knock coming from the engine from what sounds like cyl four. Did a pressure test which gave me the following:
cyl 1 - 8 psi
cyl 2 - 11 psi
cyl 3 - 12 psi
cyl 4 - 9 psi
Also the oil buzzer is coming on if the car is driven for a while or if revved to 2000 rpm. Goes off if a sharp blip is given to the throttle.
Also changed the thermostat and topped up oil.
There is very small traces of oil in the water and white gunge in the oil, but I'm not sure if this is from prior to the head gasket being changed.
Not yet changed the coil.
Any advice for me?
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Have you re-fitted the old bottom end by mistake? :D Worse compression than before!
Blue smoke suggests burning oil, white smoke is trying to burn coolant, so blueish white maybe a bit of both.
Everything you've said seems to point at head gasket, but as it's the same with 2 different blocks and new head gaskets maybe the head is cracked in a couple of places, causing cylinders 1 and 4 to burn oil and/or coolant.
Oil buzzer could be a dodgy pressure sender, but it could be that you actually have crap oil pressure.
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It's driving me insane. If the heads cracked it's not noticeable to the eye. Haven't had it pressure tested though so there's every chance.
It could be that the block needs skimmed too.
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Took the car to be checked out by a professional. He's told me he thinks the charger has blown a seal due to the amount of oil in the charge pipes. He also believes this is the cause of the bottom end giving way again due to excess oil causing pre detonation in the combustion chambers leading to the failure.
In short, I need to rebuild my charger and repair / replace the bottom end again to fix the problem. :(
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try just a charger service at first and see how that goes.
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Yeah, Pete's guide is gonna come in very handy :)
The knock from the engine is worrying, but we'll see what happens.
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boris what bs mate hope you sort it but just to let you know i have got my spare engine for sale cheap as missing a couple of peripheral bits.
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Well the good news is that the charger is ok and only throwing out the amount of oil you'd expect without having the boost return mod done on the car. The bad news is that its still not running right after changing the coil, dizzy cap and rotor arm and cleaning out the charge pipes and intercooler. Definately a problem with the bottom end, probably piston rings.
As I can't afford to be spending any more time or money on the car (and also that I have something else lined up), I'll definately be selling it now. So if anyone's interested, pm me. ;)