Engine rebuild update...

tango · Post by **tango** » Sat Nov 05, 2005 1:35 am

It's been a while since I've been working on this engine and many of you would have thought I was done. Several things have gotten in the way. Most notably the fact that I couldn't find a set of main bearings. I found a set on eBay and I've been working on and off on it since then. I'm finally done with the teardown/cleanup and am in the process of reassembly.

During the teardown I observed all but one cylinder had NO ridge. NONE. Cylinder 4 however had a very strange ridge where it wasn't round, but was sorta half-moon in shape. The cylinders were consequently bord and sleeved back to spec and I took to reassembly. I also took the liberty of having the crankshaft pulley rebuilt as it was its failure that caused the rebuiild in the first place. I chose to rebuild becasue it is almost impossible to find one for the distributor ignitioned models like mine. Anyway, it was yesterday while installing the piston rings that I realised what might have caused the odd ridge to develop. As I installed the lower compression ring on piston #4 I noticed that the ring wouldn't turn in the groove. There was a collapsing of the landing. I'm assuming that this situation obtained while the engine was running and caused the ring to be cocked. This cocking dug into the cylinder walls and voila. Ridge. On closer inspection this collapse of the landing was actually a crack! The piston is now useless. I have already spoken to Island Motors and they have them in stock. I'll be picking one up on Monday.

I expect to be done with this project by the end of the coming week. At least the engine will be in running order by then. I'm gonna be trying to install it and give the car a test run by the end of the following week. I'll keep you guys posted.

Post by **PrecisionBoost** » Sat Nov 05, 2005 10:52 pm

So you still have your Daewoo??

Which model do you have??? (I was thinking it was a Lanos)

For some reason I thought you got rid of it...... you were off the forum for what seemed to be a year or so and I was surprised to see you come back.

Well... I'm glad you've sorted things out.... it sounds like things are coming along nicely.

Do you plan to modify the engine at all?

MMamdouh · Post by **MMamdouh** » Sun Nov 06, 2005 8:58 am

yeah right, go turbo your woo Tango... it will be fun :lmao:

MMamdouh

Post by **PrecisionBoost** » Sun Nov 06, 2005 6:50 pm

mmamdouh wrote:yeah right, go turbo your woo Tango... it will be fun :lmao:

MMamdouh

Actually..... he was one of the first guys to do this.... it was well before your time on this board from what I remember.

If you do some searches with "turbo" and Tango as the author you will probably find a number of articles..... if I remember correctly he had some serious problems on the journey to boost.

MMamdouh · Post by **MMamdouh** » Sun Nov 06, 2005 7:12 pm

yes i know that man... maybe i am new here but me and tango goes a long way back on the daewootech yahoo group.

i know tango faced so many troubles after putting the turbo and ended up breaking his MAP... we were discussing a 2.0 swap for his car and i said it will be even better to turbo it as well and the man showed too much rejection for the idea of a turbo, seems he had enough already with the old one.

i only mentioned that 'cause it was funny as i think Tango will go ballistic whern he sees my suggestion and probably will come yelling:

NO MORE TURBOES FOR ME!

Tango: any comments??

MMamdouh

tango · Post by **tango** » Tue Nov 08, 2005 5:07 am

LOL!

Mamdouh you know me all too well!! That's EXACTLY what I would have said (if you didn't already say it!). To answer 'Finder's question though, no. No more mods for me. Not on the 'Woo, not on any other car I own. I realise that I'm getting older and I don't have the disposable income and even less patience for that sort of thing now. My country is falling apart at the seams and the cost of living is sky-rocketing. Cost of fuel world-wide is at a car-discouraging level and it seems to be getting worse, with only small moments of seeming recovery. My plans for the 'Woo are simple. I'll finish my rebuild and sell her. To answer 'Finder's other question, she's actually a 1995 Cielo GLE. A shade bigger than the Lanos (actually bumper to bumper she's longer than a Mitsubishi Galant!).

I went to Island Motors today and picked up the piston. I had a minor scare because neither the Cielo nor the Lanos parts manuals showed any in stock. However, when the Racer manual was consulted, they showed several in stock. I was a bit surprised that the parts numbers are different for these cars, seeing that the parts are identical. Very strange indeed. Anyway, as has been the case for over a year now, they STILL have no crankshaft pulleys <sigh>. I've taken the liberty of having the old one rebuilt and it seems to be okay. Now I'm off to the machine shop this week to get the piston installed on the con rod. Stay tuned.

tango · Post by **tango** » Sat Nov 12, 2005 3:26 pm

The pistons are now in, with the broken one replaced. The bolts are all torqued to spec and she's turning uniformly, if a bit on the tight side. The oil pump has been primed and installed and come the week of the 14th I should be pretty much done.

tango · Post by **tango** » Fri Nov 18, 2005 5:34 am

Ran into a little snag on Monday with me realising that the waterpump I had was a bit different from the old. There was a metal plate under the pulley and this affected the cambelt shroud being able to fit. Tuesday Morning I called my mechanic in Kingston and he said that this water pump is actually for a Racer (Efrain, you listening?), they are otherwise identical so all I had to do was to cut the plate off. I took a pnumatic cutting wheel and did the honours later that day. I then used a grinding wheel to smooth the corners round, and then a brush-wheel to finish things off. GMDAT would be proud!

Today was a good day. The cylinder head is now mounted and the bolts torqued (18lb-ft + 70degs +70deg + 30degs). Everything turns nicely and looks good to go. I'm right on target. All that's left is to fit the external bits and then drop her in.

tango · Post by **tango** » Wed Dec 07, 2005 11:59 pm

Well folks all the internal bits are fitted and torqued. The rebuild is complete! Most of the external bits are also installed and today I dropped her in. She gave a little fight but I got her in and bolted everything in place. Come tomorrow I'm gonna be torquing all those bolts and attempting to start her up. Wish me luck!

I know you guys must be fuming about pictures and all that but trust me, it's hard taking pictures with greasy hands etc.

lanos2001 · Post by **lanos2001** » Thu Dec 08, 2005 12:05 am

can't wait man.

nick

daftmajin · Post by **daftmajin** » Thu Dec 08, 2005 12:43 am

tango wrote:Well folks all the internal bits are fitted and torqued. The rebuild is complete! Most of the external bits are also installed and today I dropped her in. She gave a little fight but I got her in and bolted everything in place. Come tomorrow I'm gonna be torquing all those bolts and attempting to start her up. Wish me luck!

I know you guys must be fuming about pictures and all that but trust me, it's hard taking pictures with greasy hands etc.

Best of luck!

MMamdouh · Post by **MMamdouh** » Thu Dec 08, 2005 12:51 am

best of luck man!

MMamdouh

kroz123 · Post by **kroz123** » Thu Dec 08, 2005 1:20 am

Good luck man

AcingTeam · Post by **AcingTeam** » Thu Dec 08, 2005 2:08 am

lanos2001 wrote:can't wait man.

daftmajin wrote: Best of luck!

mmamdouh wrote:best of luck man!

rr__kroz123 wrote:Good luck man

-Igor

tango · Post by **tango** » Tue Dec 13, 2005 12:45 pm

The rebuild has ended!

At approximately 3.30PM yesterday she turned over and started for the first time. It started first click after I sorted out a mix-up with the distributor module lead and the coolant temperature sensor.
At present I have a leak at a water hose (needs a locking clamp, as opposed to the spring-loaded one it came with). The oilpan that I repaired (removed the oil return pipe that I fitted when I turbo'd) leaks in that very spot. Back to the drawingboard with that. I may have to get a new one. I'll keep you guys posted.

That said, she's rumbling as usual. I'm really happy that it's done.