No problem with the engine (except for a great big hole!)
This car was recently brought into us to diagnose after it made a funny noise, sparks flew out and then the car stopped working on the park way. The customer had been told that the funny noise was due to her putting no oil in it, even though she had been putting in a litre a week and that there was no problem with the car.
After removal of the cam cover, we found cam followers no longer in position and big lips on the cam shaft lobes where the cam shafts had worn. The chain was also slack where it was about to jump off.
We advised the customer there was a multitude of problems and there were the following options: -
1) Cut their losses and scrap the car.
2) Remove the head to replace damage valves and check for any other damage, this would include replacing at least one valve, set of hydrolic lifters, set of followers, pair of cams and a chain kit. This is the basics that would need to be done if no other damage was found whilst checking the engine and could be costly.
3) Complete engine change. We found a reasonably priced engine on Ebay and advised the customer of the item number and gave a cost to replace the engine which would most likely work out cheaper than doing the head work.
The customer decided to go for option 3.
Thursday day the engine was removed from the car...
... and the big problem was found!
This little hole was hiding behind the drive shaft!
We have not investigated further but the assumption is that more than likely a conrod end cap had broken and decided to place itself out of the engine, this would explain the sparks the customer spotted when going up the road. The right choice was definatley made to change the engine as we more than likely would have found this problem whilst replacing the head as the piston would not be moving up and down.
Thursday evening we went to pick up the new engine the customer had purchased and delivered it to the workshop.
This is the new engine, notice no hole!
Friday we got to work to put the engine back into the car. This new engine was out of an earlier model of the same car so bits were different - it was however a lower mileage engine that the original.
We adapted the engine by swapping inlet and exhaust manifolds, egr valve, thermostat housing, clutch, fly wheel, dipstick and coolant temperature sensor. It was then ready to bolt into the car.
Once the engine was in place, we bolted it back up to the gearbox, re-fitted starter motor, alternator, auxiliary belt and air-con pump. All water pipes were re-connected, engine mounts back on, all wiring re-connected, fresh anti-freeze and oil and it was ready to fire up.
The car fired up first time and ran really sweet - one of the best sounding engines of this type we have heard! The engine was then ran up to temperature until the coolant fan kicked in and was checked for any leaks. It was then sent out for a test run, all the levels were re-checked and the customer was happy to have it back so quickly. The customer also commented that the car was quieter than when she had originally brought it.
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