"Keep a Journal: How else are you going to get a good look at who you were?"

Saturday, August 29, 2009

I've been on tenterhooks about this engine.

See, all through the overhaul and etc. I've been plagued by the thought that I was missing something obvious.

Let's recap:

This van was sold cheap because the #1 cylinder was full of (fresh!) coolant and the engine had hydraulic-ed ("just a little") when somebody tried to run it. I guess I shouldn't have insisted on seeing it turned over before buying it.

The engine compartment was extraordinarily dirty. So was the engine...from about the top of the block downward. Still is.

There was no obvious damage to the head gaskets. In fact, they appeared to be new O.E.M. gaskets.

There was no obvious damage to the head.

There was no obvious damage to the block or cylinder liner.

There was no leakage I could detect across the manifold gaskets. They were near-new O.E.M. as well. There was quite a bit of gasket residue on the head side of the intake, but not from those gaskets.

The cylinders have been honed. Recently. By an amateur. Someone used a de-ridging tool on them as well. That part, at least, was properly done. I don't know if the rings and crank bearings were replaced...but it isn't really important now.

Conclusion?

Someone attempted to overhaul this engine just before it was sold to me...and it went wrong.

I'm almost certain it was a D.I.Y. job, as well.

I'm using updated and upgraded aftermarket gaskets (Fel-Pro "Permatorque" brand). I've carefully cleaned all the mating surfaces on the head and block, in addition to having the heads themselves "shaved" at Heads Unlimited Machining in Whalley. I've replaced the seals on the coolant transfer pipe and even replaced one of the pipe sections. I've also put a new seal on the outboard head timing shaft where the distributor drive is. I'm having a little difficulty with the seal on the inboard head. I may have to leave it where it is.

In short, I'm doing everything I know how to do to make sure the job goes right. Take the torque settings for the head, for instance: the instruction sheet that Federated includes with the Fel-Pro gasket set gives the head bolt torque as 80 ft-lbs. That is indeed the correct torque...

But the Haynes manual AND the Chrysler shop manual both recommend torquing the heads in three separate stages: to 50 lbs first, then to 65 lbs, and finally to 80 lbs. Going straight to the final torque using the pattern that Chrysler recommends might actually warp the heads, once the engine is under operating load and pressure.

And heaven help you if you don't torque them according to the pattern...

Anyways...wish me luck people, I may need it.

More tomorrow.

Wednesday, August 26, 2009

Progress report: part III

I'm dragging my nether regions on this project. So finally about 6PM this evening, I said to myself, "I ought to at least get the prep work done".

That took three hours.

First up was the sensor plug on the transmission. The plug itself is fairly robust. The wire leads attached to it aren't. I got the new plug spliced in and then just for good measure ran some heat shrink tubing around the leads that will add another layer of protection.

Next was the intake pipe from the rear of the water pump. As I've mentioned before, the pipe is in sections with collared couplings between them. The junction where the heater core return line joins the radiator return line was badly corroded. There was also some pitting on the inside of the pipe. Causing me to yank yet another replacement part from the '94...

The engine compartment is extraordinarily dirty. What I really need to do is blast that puppy out with a pressure washer. Hmmm, I wonder if Manny would be willing to loan his out?? Or perhaps my generous (ex) father in law Bob would be willing to let me have his for a day or two.
Or, I could just try the jet nozzle on our garden hose...

I just don't see the sense of re-assembling that engine with newly machined parts and shiny new seals and have all those crud coated fenders and body panels surrounding it.

I also set up the worktable in the garage and spent a half hour getting the manifolds back on the heads. I managed to find enough pictures to figure out where the various hangers and extra bits belong. After all, I no longer have an assembled engine to look at; I'm doing the rest of this job from memory!

Saturday, August 22, 2009

Progress report: part II

Finished the breakdown on the '94 engine. I still need to extract the fluid sensor plug on the transmission housing. The engine is secured and the '94 is ready to be towed. I'll be starting the re-build as soon as I've got the transmission sensor repaired. I still need a couple of tires for the cavalier. This means I can't actually move the '94 until I've got the '95 running, as I will need a vehicle to get the wheels over to action tire. Once I've got a full complement of wheels and tires for the cavalier, I'll have the '94 van towed away and start on the cavalier's repair.

Sell the '95 once the cavalier is running.

Sell the Cavalier, once I find a suitable replacement vehicle.

If I do.

Along the way, we'll be getting rid of a mountain of JUNK from the garage and several items from my suite I'm not currently using (and am probably never going to use).

Wednesday, August 19, 2009

Progress report:

I've spent nearly three hours on the '94 engine dis-assembly. Not much progress. I've got the intake manifold off. I'm already contemplating "mixing and matching" parts as the '94 engine has higher mileage, but its parts are in better condition. I've also finally figured out a way to test the block on the '95 to see if the cylinder liner leaks or not. The '94 had a broken vacuum line. It figures - I really was at a loss to figure out why it ran so roughly and why the timing wouldn't stay put. This particular vacuum line was connected to one of the widgets that modifies the ignition timing, of course. Broken fittings; good thing I have a spare set.

Add the broken vacuum fitting to the transmission sensor connector and the broken brake light switch to the list of annoying minor details that have to be covered before I can put the engine back together on the '95. So much to keep track of. I'm already committed to using the inboard exhaust manifold on the '94 with the '95, as the manifold on the '95 has a hairline crack running right up the middle of it on the topside. I do believe I'll be consulting the manual fairly frequently before this job is over.

Kerry Newton called earlier this evening and - miracle of miracles - he has a Honda for me to look at. If I'm not going to keep the Cavalier after repairing its steering, this Honda might be a good answer to the question; "what will I be driving this winter?"

All in all, this project is looking like it will take some time; a few weeks at least. I just have to keep plugging away. I will probably make some real progress this Saturday, as we have no overtime planned at work...for a change. I hope the weather holds.

Final note: Grandma Sanderson and Aunt Pat arrived from Estevan last week. They're doing a tour of the BC relatives. They dropped in at Audrey's place a few times and I was able to visit them with the kids. Sunday Grant and Kathy and their kids and me and my kids all had an outdoor picnic in Audrey's backyard. We all caught up...and the kids got to see their cousins again. L was nowhere to be seen for either event. Grandma S looks in good spirits and it is apparent that the trip has been a good one.

Tuesday, August 18, 2009

The Ex bought a new car...

Well, it's new to her.

L bought a 2003 5 speed cavalier. She is probably thinking that I won't be able to resist the impulse to fix it when it breaks...I think I won't have a problem...

Oh, I may help out on occasion...just to be a nice guy. Irony: this is exactly the sort of vehicle I was pushing as a replacement for the white '96 cavalier -- two or three years ago.

What brought on this extravagance? The '96 lost it's steering. L was noticing puddles in the driveway (as was I) and that the steering on the car seemed to be getting a little "heavy". She finally brought it home one day early last week complaining of a "grinding noise" and claiming that the garage she took it to wanted to sell us a new tie-rod end for only 300$. I took it for a short spin and after parking it asked her, "when was the last time you filled up the power steering fluid?", "It's fine...I think", she answered.

The reservoir was empty. Bone dry.

I topped up the fluid and the steering response was almost normal. Renewal of pressure in the system busted the leak wide open...and it was dry less than two days later. She had it re-filled and it now was shaking so bad the garage now claimed the entire rack was shot. I don't blame them, that's what I thought too...

...at first.

The Haynes manual is fairly specific on the procedures for replacing the hoses, seals, or even the entire assembly. All of the above procedures include a *vital* final step:

If the fluid level in the system has gone below minimum...you have to bleed all the air out of it before it will work.

Otherwise the air in the system will cause the wheels to track really roughly...and inputs to the steering linkage will have the wheels jigging all over the road.

Which is what it's doing now.

Even if the entire assembly is toast I can get a replacement for under 400$. The new hoses will cost 110$. The job will involve jackstanding the front end of the car and supporting the rear engine support frame with a jack. This means I better finish up with the '95 caravan soon, because my stands and floor jack are currently supporting it. L sold me the cav for 50$, the value of two tires she put on it earlier this year. She's keeping the other new tire, so I will need a replacement rim. This will be an additional 25$ at a wrecker. Getting a couple more salvaged tires swapped around at someplace like action tire will probably be another 50$ or so.

I'm looking at 600$ to get the beast running again. It's worth about 1000$ tops in running, aircared condition. Perhaps I ought to sell it as well. Still leaves the question of what I'll be driving once the snows come...