Mk3 Gold saloon

[MARINAMAN480]

1 step foward 5 back , 3 broken water pump bolts and 1x broken block trying to get 1 out

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[Gee tc]

Looks like a face in that block Lee

[MARINAMAN480]

Quick update , Managed to save the block ,drilled the wonky hole out with an 11mm drill then tapped it out to 1/4in bsp for 2 reasons 1: its the biggest tap i have and 2: Being a Gas/Plumber engineer i have lots of bsp plugs.
Fitted and old water pump and drilled a 5mm hole in to the plug as its not dead center then tapped that out to M6 to match the rest of the water pump bolts.
Then gave the water jacket a good wash out.

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[ScreamingLordStokes]

Phew, that's a relief! Nice to see a bit of good old fashioned engineering. Great rescue

[MARINAMAN480]

Engine all stripped down ready for new bearings.
And one snapped main bearing bolt, which weirdly came out ok although felt loose , didn't know it was snapped unitl it fell apart in my hand.

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[MARINAMAN480]

Cylinders honed out , new main,big end bearings and piston rings fitted, and a nice shiny sump fitted, but got to come off again as its quite tight, takes a fair bit off force to get moving but once moving it gets easier, but still not as easy to turn as before strip down, As this is the first engine i have rebuilt will strip it down again.

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[trunnions ftw]

Which bits caused the tightness, doing up the bearing caps or after the pistons went in? Piston rings are often fairly difficult to stroke over fresh honing especially if its not plateau honed.

[Kilroy]

You may find that it is just the new rings making the crankshaft difficult to turn.

I have had a lot of trouble with the oil pump seals leaking in the past. It is a good idea to spend some time smoothing the surface where the seal runs on the crankshaft just forward of the keyway.

[JubileeNut]

Whenever a new seal is fitted you should cross hatch diagonally the smooth area all the way round with wet and dry to break up the smooth surface to allow the seal to bed in properly. or not put the seal in the exact same place.

[MARINAMAN480]

Found out what caused the engine to tight ,
It was 2 big end bearing caps on wrong way round , I didn't realise there was a right and wrong way , you live and learn.

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