5 GT Turbo C1J rebuild.

[sparkie]

Just another C1J build for someone.
How it arrived....
Water pump was siezed too.

 

[sparkie]

Taking it apart...
Not much wear to the chain tensioner...
Standard cam sprocket...

It was at this point I realised the sump was still full of oil....
The C1J fairy leaving nice presents for me....



Not great....

 

[sparkie]

So the owner of the engine and I decided to reuse the pistons, but change the liners and rings. Reason being is that a guy local to us was selling a new set of kolbenschmidt liners and pistons with rings for a volvo 340, for a very good price. So use the new rings and liners and jobs a good'un. The crank is in good shape, the oil pump is shot.

 

[sparkie]

Carb pieces media blasted and ultrasonically cleaned.


Inlet manifold heated up and the water ports removed.


Head needs a good going over...


Time to clean up the block...


Caustic Soda and hot water...

 

[sparkie]

Carb nearly finished...

Aluminium pieces, etch primered and painted...

 

[Chris74#]

Carb nearly finished...View attachment 209417

Aluminium pieces, etch primered and painted...View attachment 209418

View attachment 209419

View attachment 209420

View attachment 209421

@sparkie thus will be my bible for stripping and rebuilding mine early next year! As much detail and important notes as possible please!!

 

[Chris74#]

Carb pieces media blasted and ultrasonically cleaned.
View attachment 209412

Inlet manifold heated up and the water ports removed.
View attachment 209413

Head needs a good going over...
View attachment 209414

Time to clean up the block...
View attachment 209415

Caustic Soda and hot water...
View attachment 209416

How long do you leave it in there mate? I had a bad experience with the caustic soda and my gearbox casing! Although I now know not to put ally into caustic soda!!

 

[sparkie]

How long do you leave it in there mate? I had a bad experience with the caustic soda and my gearbox casing! Although I now know not to put ally into caustic soda!!

I left it in for a day, then took it out and jet washed it. Then using fresh hot water and a new bottle of caustic soda I've dunked it again. It's on day 3 now. You must remove the engine number, else it gets eaten away in a couple of hours. Use the thickest feeler gauge, slide it under the engine number plate so it is touches the rivet, then use a small hammer to knock the steel feeler gauge through the soft aluminium rivet. Repeat both sides, keep the rivet heads and RTV them back on later.

 

[sparkie]

@sparkie thus will be my bible for stripping and rebuilding mine early next year! As much detail and important notes as possible please!!

Remember to mark the conrod caps and the conrods, to keep them together as matched pairs.

 

[sparkie]

So I got the jetwash working and sprayed the block clean with water.
I then took it inside and dried it out.

Then back outside for adhesion promoter and first coat of paint.

I like to clean up the bolt holes afterwards with a tap and I'll clean up the mating surfaces with a razor blade, sandpaper and scotchbrite.

 

[Adey]

fantastic stuff, anything trick going back into it?

 

[sparkie]

fantastic stuff, anything trick going back into it?

A 264 deg cam and uprated springs from Autosprint, and that's about it.

 

[sparkie]

Another day, another coat of paint.

 

[DaveL485]

Any reason you're not vapur blasting, other than the obvious?

I bet you could do one of these blindfolded!

 

[sparkie]

Any reason you're not vapur blasting, other than the obvious?

I bet you could do one of these blindfolded!

I have access to sandblaster for zero cost. If you wanted to be picky I'd say it also leaves the surface ripe for paint, as the bare aluminium loves to oxidise in moist conditions.

 

[sparkie]

Good day...


Good day....

Errr, not so good day...

 

[Adey]

will it dig out with a pick or is it a machine shop job to re machine the seats?

 

[Chris74#]

Good day...
View attachment 209463

Good day....View attachment 209464

Errr, not so good day...View attachment 209465

That block looks the dogs wanger! What is the last photo of?

 

[sparkie]

will it dig out with a pick or is it a machine shop job to re machine the seats?

It's eaten the block material away. The solution is more sealant, or chemical metal and shape it.

 

[sparkie]

That block looks the dogs wanger! What is the last photo of?

Where the liner sits. It's corroded.