Big End Replacement Tips?

Myles1ZZ · March 24, 2017, 11:18

Hi All!

I'm not having much luck with my new MK3. After fixing a previous ticking noise (loose alternator bolt) I now have a knocking noise and my mechanic tells me the big end bearings have gone. I've read a lot of posts on here and other forums which suggest it may be worth popping the sump off and replacing the shells after checking/cleaning the crank shaft.

The mechanic after listening to it proclaimed that it would need a new engine and quoted £600 labour if I supply the engine s:flame: :flame: s:flame:

I'm hoping that the crank is fine and that the new shells will solve the problem. For those who have done this before: what do you think the chances are of me getting away with just the shells? Does anyone have any tips/tricks or pitfalls for me to be aware of? I've already read pretty much every how to guide I can get my hands on but it never hurts to get extra info from the experts.

I'm just worried that if the shells do fix the problem it will still happen again unless I track down the cause. The engine is a 1ZZ in a 2001 car with 103,000 miles on it. It doesn't seem to be burning oil and it's had a decat manifold fitted at some point. I did notice that when I changed the oil it was black as pitch and judging from a few other issues on the car the previous owner had neglected it. Could this have caused the bearing issue?

Any tips/tricks welcomed!

shnazzle · March 24, 2017, 11:30

Let me be the first to say....

Hehehe hehehe... "big end"

All joking aside. Carolyn and Jon did something very similar last year. Worth a shout

Carolyn · March 24, 2017, 11:34

Nine times out of ten, you'll be fine with just re-shelling. Very often it's caused by a combination of a low oil level combined with very hard driving on long right-handed bends. (Allows the pump to suck air.)
Black oil can indicate stuck oil control rings. Keep an eye on your oil level. Lot's of people live with engines that go through 1ltr/ 800-1,000 miles with no probs. (So long as you keep it topped up).
You won't see blue smoke and it will pass emissions test.
The sump is pretty much glued on, so use Stanley knife blades to cut as much of the sealant as you can. If you just try to pry it off, you'll bend it.
Plenty of Dirko Elhring sealant (or equivalent) when you put it back on. Oh and clean it out thoroughly.

There (with luck) should be no crank damage. (They are pretty tough). Clean any white-metal build-up off the journals with fine wet-and-dry.

I've done two with good results.

Myles1ZZ · March 24, 2017, 14:00

Thanks for the replies! I only got the car about 2 months ago so I don't know the long term situation but the oil was up to the mark when I got it. I've done about 100 miles since with no oil consumption but then again the dipstick isn't the most accurate I've ever seen... Could anything else cause this? I've read a post about a clogged oil screen or something? The oil filter the last owner had used was a cheap and nasty "delphi" or something like that which I've also read can cause issues.

Thanks.

Carolyn · March 24, 2017, 14:41

You have nothing to lose by pulling the sump. Just a couple of hours' work.

Then you'll get to see how much sludge is in the engine, how clean the screen is on the oil pickup, what state the crank is in and so on.

When you've pulled it, report back on what you've found and the club will help you through.

Myles1ZZ · March 28, 2017, 14:04

Right. Managed to get some free time over the weekend and got the sump off. By the looks of it someone has had it off before at some point as there were about three different kind of bolts on it of different ages. With any luck I'll get the shells off at the weekend for a proper look at the crank.

I'll post some pictures here for an opinion in the mean time:

Oil pickup looks clean enough...

Pretty dirty though.

Is this the code I need for the new Shells?

Thanks!

Carolyn · March 28, 2017, 14:57

It's stamped on the caps.

Myles1ZZ · March 30, 2017, 14:28

Good news, I think...
Managed to find the dodgy bearing.

Three of them look like the one on the right. The one on the left is from the cylinder furthest away from the oil pickup.

Here is a picture of the journal that had the dodgy bearing:

It feels smooth enough to the touch so I'm hoping I've caught it in time? I'm not sure whether to just leave the journal as it is or try polishing it with some sand paper and WD40. I'm tempted to leave it in case I donk it up s:lol: :lol: s:lol:

The caps and the shells have a "2" stamped on them which I take it is the size of replacement I need.

I'm off to try and get all the oil out of my hair. Thanks for all the help! s:bowdown: :bowdown: s:bowdown:

Carolyn · March 30, 2017, 16:35

All the shells are done! Never mind, polish the crank and put in #2s and you're good. Just gently remove the white metal build-up. You won't hurt the crank. 600 wet and dry.

Myles1ZZ · March 30, 2017, 16:51

Thanks for the advice Carolyn. I thought it was only the one that was done? Is the shell on the right gone as well? I've been trying to order the shells online but apparently I need a bit more info than the number on the cap. Would you happen to know how I work out the part number?

Carolyn · March 30, 2017, 16:57

Good shells don't have mark on them.

Go to Toyota if you want precisely sized shells. Or, at least talk to Toyota to get the part number.

Myles1ZZ · March 30, 2017, 17:03

Okay. So there is no acceptable amount of wear for a shell then. At least it wasn't as bad as the one that was chewed up. Explains the metal debris in the oil intake.

Carolyn · March 30, 2017, 17:04

Sent you a Private Message.

Myles1ZZ · April 18, 2017, 11:17

Got the sump back on at the weekend, went on a 50 mile round trip and the engine is running sweet! The knock is completely gone and the engine revs more freely than before. Just in time to get the top down for summer s:D

s:D

Thanks for all the help!

Carolyn · April 18, 2017, 11:19

Result.

jonbill · April 18, 2017, 11:23

Well done

1979scotte · April 18, 2017, 17:46

Great news.

lamcote · April 18, 2017, 18:35

Carolyn saves another 1zz, it must be quite a long list by now, well done.

Carolyn · April 18, 2017, 18:49

Myles did the saving. I was just the coach!

smarty72 · April 18, 2017, 19:00

Pleased for you Miles, well done. Might be a good move to break out the OCD over checking the dipstick for a few weeks.

Great coaching Carolyn.

Myles1ZZ · April 19, 2017, 11:22

Yeah, I'm checking the oil every day at the moment. No loss yet as far as I can tell from the terrible dipstick. I think the previous owner was rather lax with the oil changes judging by the way the car has been maintained. He had 3 different kinds of spark plug in the engine when I got the car!

Can't praise Carolyn enough. A real life saver!

smarty72 · April 19, 2017, 15:53

3 kinds of spark plug [emoji20], that's the ultimate penny pinching, they cost pennies....

Myles1ZZ · April 20, 2017, 09:23

I know right. I replaced the whole set for £4.50! Cylinders 1 and 4 had the standard NGK plugs, 2 had a three pronged Champion plug and 3 had a two pronged NGK. Wouldn't be suprised if the oil I drained out of it was Tesco Value mineral oil!

smarty72 · April 20, 2017, 10:19

Quote from: "Myles1ZZ"I know right. I replaced the whole set for £4.50! Cylinders 1 and 4 had the standard NGK plugs, 2 had a three pronged Champion plug and 3 had a two pronged NGK. Wouldn't be suprised if the oil I drained out of it was Tesco Value mineral oil!

Maybe recycled from the local chip shop??

Fingers crossed for you..