Engine Rebuild

[jimjamjo]

Hi

 

I did a rebuild on my Galaxy about 18 months ago with 4 new standard pistons. It was fine for 12 months but suddenly conked out about six months ago - almost total loss of power and lots of smoke.

 

Finally got round to leakdown testing it a couple of weeks ago - 2nd-4th chambers fine but no pressure on no 1.

 

I've taken the head off and got the engine out again groan. no1 piston is chipped on top and looks like detonation 'melting' the crown between the inner hole and edge (pics to follow). Got the head checked over and that's fine.

 

I could get a nearby mobile mechanic out to rebore 1 cylinder and pop an oversize piston in... or strip the block and get the full set(again!). Can anyone give me advice either way bearing in mind that I'd like to get another 4 years/ 60,000 miles out of it. I'd much rather go for the one cylinder option to save time and money but not if it ends up driving like a tractor. Also, there's 170k on the clock so far.

 

 

1998 1.9TDi

[jimjamjo]

Forget that - No 2 piston also worn :ph34r:

 

Also topside of each bigend shell pitted

[jimjamjo]

Any one know where to get an 1z engine around Manchester? (Looks like rebuild would be around

[turk90210]

well from personal experience and from others I WOULDN'T just rebore 1 cylinder as it will throw the balancing of the engine out and create other problems. have you done any mods to the engine or is it all standard, also did you set up the timing properly!

Its hard to say what has caused your problem without a thorough examination, my best advise would be to post your problems on http://www.tdiclub.com/ which is an American site dedicated to diesel engines with alot of knowledgable people (anyone with a petrol engine forget it they dont want to know)

[jimjamjo]

Thanks for the advice Turk

 

Bought an Audi A4 1z engine off eBay:

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?Vie...em=250121951237

[jimjamjo]

Just finished putting the A4 engine in. In case anyone's interested heres some particulars:

 

The 1z engine came with the same injection pump, starter motor, flywheel, turbo, cylinder head

 

The A4 items which were different:

Clutch, Gearbox, manifolds, oil filter assembly, water pump pulley, engine front and rear plates, mountings, drive shaft mounting bracket, turbo to head oil feed pipe (on the A4 its turbo to oil filter housing), power steering bracket, coolant pipe on head

 

Also, the 4 holes for the left engine mountings on the A4 are M8 - not M10. So these need oversizing and tapping. I'd never done this before but it was surprisingly easy. Using a 9mm drill bit, drill out the hole letting the drill do the work and then wind a 10mm tap into the hole.

 

So with the tapping and different items, its quite a big changeover and added a day or so to the job.

 

Main points:

 

1. change the oil filter housing over with the water pump assembly at the same time. You could leave the A4 filter housing if happy with using A4 filters :) . This would leave the turbo oil feed going to the oil filter housing instead of the head (the temperate gauge swaps over with the oil feed)

2. the A4 front plate covers 2 holes for the Galaxy left engine mounting so remove camshaft pulley, injector pulley, timing tensioner etc and remove the front plate. Retap the 2 holes to M10 as above before you put the new front plate on.

3. I used the A4 head with manifolds - the manifolds are a different size but everything else fits in with them ok as long as you swap over the turbo to head oil feed pipe.

4. remember to change the engine rear plate over when you swap gearboxes

5. the 3 holes for the Galaxy driveshaft mounting bracket were the right size but all rusted up on the A4 and also needed retapping M10.

 

 

Nothing caused a major problem apart from removing hose clip from turbo vacuum pipe with a hangover on Sunday morning - ended up snapping the little f**ker off.

 

By the way, the engine off eBay was showing moderate leakage from all four chamber on a leakdown (about 50%). It did smoke a fair bit for the 1st 5 miles but seems not too bad now - to be honest I've had enough of smelly old diesels so its going in Autotrader.

 

Here's a pic of my new 2.3 petrol Gal :rolleyes: