/edited to include some comments as requested....
Most of us are curious of exactly what the inside of a wasted engine is like...bearings....bores....valves etc.
So, to indulge all your voyeuristic tendencies, I am putting the details of the stripdown of my old 1zz as well as the subsequent rebuild.
History: engine was burning litres of oil and had knocking bearings - probably from when it used an entire sump worth of oil over 200miles of motorway driving when I was on my way back from London....At the time of 'retirement' it was working fine - apart from what I note above.
I will be repairing & rebuilding this properly (already built one engine that I am running right now) and then trying to find a buyer.....
Enjoy!
The first set of pics (03 JULY 2008) speak for themselves....
Cylinder head off. You can just see the tops of the exhaust valves (nearest the floor). On the inlet valves, the lifters are still in place - these are the really shiny bits - 8 in a row). These act as shims to set valve clearance from the cams (removed in this pic)...V important to check the shim sizes when installing new cams. The lifters are pretty expensive - £13+vat each from Toyota....
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0033.jpg)
This shows the top of the block with the cylinder head removed. The big bit stiking up is the side cover / timing chain cover. You can make out the timing chain and the tensioner (RHS of chain) as well as the chain guide (LHS of chain). The side cover is sealed to the block using RTV sealant. Use the Toyota sealant when putting this back on as it contains the water pump and a leak of coolant past the RTV sealant can be into the sump. Thus contaiminating the oil and possibly wasting your big ends.
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0034.jpg)
Major carbon deposits. The orange colour is basically organic varnish formed by a combination of high temp, oil contamination & fuel vapour. Nasty stuff. This is basically the stuff that 'glues' the rings on these (most) engines and gives oil use issues.
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0029.jpg)
The bores look bad here but actually they are in surprisingly good nick. I was very suprised that the carbon deposits did not damage the bore.
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0030.jpg)
All these carbon deposits fell from the cylinder head just whilst I was removing it. I did not put it there....probably it is down to the 10 odd litres of oil that the engine has consumed recently...
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0031.jpg)
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0032.jpg)
The carbon contamination of the combustion chamber is unbelievable. It really is as thick as it looks - in some places 2.5mm thick. Some of it flakes off but some of it takes a gouging by a chisel to get through. All repairable though....I have not see the seats yet though.
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0036.jpg)
The engine reallyt was running. It was 'popping' a lot down the exhaust. Carbon deposits like this would be the cause as they exit the engine glowing red hot and ignite excess fuel that the ecu puts in to over oxygenation of the mixture hitting the cat.
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0042.jpg)
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0037.jpg)
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0035.jpg)
nice one sj, keep them pics going, thats a real nice set of pics, and yes i am very curious as to what the dead lump looks like from a post mortem.
any chance you can add a bit of commentary as to what the problems are that you find as you go along. and how long do you think it will take to rebuild?
many thanks
E
I'm going to enjoy watching this thread, keep up the good work!
Quote from: "enid_b"nice one sj, keep them pics going, thats a real nice set of pics, and yes i am very curious as to what the dead lump looks like from a post mortem.
any chance you can add a bit of commentary as to what the problems are that you find as you go along. and how long do you think it will take to rebuild?
+1
Thats a lot of carbon!
I'm thinking that's just a bit more than carbon in there.
Good work sj, keep us updated with some commentary.
I'd also be interested in opinions into what is fixable.
Quote from: "Wabbitkilla"Good work sj, keep us updated with some commentary.
I'd also be interested in opinions into what is fixable.
Not sure if this is what Nic et al mean by commentary, but for engine virgins like myself but could you add comment to each picture about what you find (ie what the picture shows), your thoughts on why it's there and what you propose to do to fix the problem.
Would be most useful, many thanks
Quote from: "muffdan"I'm going to enjoy watching this thread, keep up the good work!
+1
I, like Roger and many others on here, am an engine virgin so labelling pictures with what you see would be fantastic.
Cheers
More updates....
Bottom of the block with the bearing cradle frame removed. Crank bearing surfaces look OK but not cleaned properly so hard to tell for sure.
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0056.jpg)
Bearing cradle. Bearings actually look fine....strange.
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0055.jpg)
Close up of bearing cradle bearings
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0057.jpg)
Con-rod cap with bearing shell removed. Again bearings look OK - maybe a bit glazed over.
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0048.jpg)
Con-rod cap removed and looking at crank big end.
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0050.jpg)
Looking at another con-rod from both sides
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0051.jpg)
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0052.jpg)
Close up of bearing cradle bearings with cradle about to go through dishwasher....the alkaline surfactant in dishwasher tablets is perfect for cleaning engines...
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0059.jpg)
Close up of piston with rings in
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0053.jpg)
...and removed. You can see the varnsh / gum / tar mixture that binded the rings up and caused oil usage
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0062.jpg)
Nearly finished cleaning stuff up. To be continued soon.....
QuoteClose up of bearing cradle bearings with cradle about to go through dishwasher....the alkaline surfactant in dishwasher tablets is perfect for cleaning engines...
How did your SF react to you suggesting that? s:D :D s:D
"Yes dear I'm just going to put my engine in the dishwasher..."
s:crazyeyes: :crazyeyes: s:crazyeyes: s:lol: :lol: s:lol:
This thread is utterly brillinat and very compelling stuff for those of us that know how an engine works, yet have never had the chance (or the space!) to strip one down and see it for ourselves. When complete, it'd be nice if this was cleaned of all the other comments and chucked in the reference section IMHO.
Top stuff matey.
Quote from: "Ekona"When complete, it'd be nice if this was cleaned of all the other comments and chucked in the reference section IMHO.
+1
Couldn't agree more
top stuff, keep it coming ta
E
Fantastic thread - thanks for all the info.
Can't see me getting the engine in the dishwasher thing past SWMBO though! s:lol: :lol: s:lol:
Cheers
Stu
Quote from: "sjspitz"...and removed. You can see the varnsh / gum / tar mixture that binded the rings up and caused oil usage
(http://i279.photobucket.com/albums/kk138/sjpitz/busted-ass-1zz/PICT0062.jpg)
Nearly finished cleaning stuff up. To be continued soon.....
A prime demonstration of why a good synthetic is a good idea. I have never seen so much gunk on the inside of an engine owned by me. Having said that, I have seen a lot more on engines owned by others that I have rebuilt. Could it bet that the famous precat failure is caused by gummed oil control rings?
Chris
Quote from: "sjspitz"/edited to include some comments as requested....
Fantastic, thanks very much...keep it going.
Quote from: "Ekona"When complete, it'd be nice if this was cleaned of all the other comments and chucked in the reference section IMHO.
Good idea Dan
Quote from: "ChrisGB"A prime demonstration of why a good synthetic is a good idea. I have never seen so much gunk on the inside of an engine owned by me. Having said that, I have seen a lot more on engines owned by others that I have rebuilt. Could it bet that the famous precat failure is caused by gummed oil control rings?
Yeah. I think that I was stiffed when I brought my car of the dealer. It turned out to have had undeclared crash damage so I had to give it a whole lot of inspection to make sure it was repaired correctly beneath underseal & carpets etc....the previous owner probably neglected the engine just as much. I have been using fully synthetic since I brought it but it was probably done before that...
SS.
roughly speaking, how many hours would it take to dismantle an engine (granted your quite experienced at it)
and 2, how long does it take to put back together.
fascinating thread this....
E