Corsa Phil 666
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Registered: 28th Nov 05
Location: Clacton-on-Sea, Essex
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Caarying on from my last thread. Rebuilt engine 800 miles ago. Driving along and took it to 5000 rpm in third. About 1 minute later coming down of the revs it stalled. It starts up and runs fine but anything over 2000 rpm theres a loud rattling knock. The RAC man said top end so i changed my cams and lifters but it's still there. I put in ARP rod bolts but could one have come loose?? The pistons and rings have 3000 miles on them appartently? Could it be rings? There was a bit of smoke when the knocking came in but it soon cleared. I think it was just condensation. Please Help!!!!!
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Warren G
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Registered: 14th May 06
Location: Kent
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knocking - bottom end fuked?
oil level okay?
new shells? etc???
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Corsa Phil 666
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Registered: 28th Nov 05
Location: Clacton-on-Sea, Essex
User status: Offline
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Had crank regrind with oversized bearings, lightened and balanced with flywheel and clutch. ARP Rod bolts. Plenty of oil. New oil pump. Can't see a reason why it would be bottom end.
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Warren G
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Registered: 14th May 06
Location: Kent
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best bet - strip engine to inspect
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Corsa Phil 666
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Registered: 28th Nov 05
Location: Clacton-on-Sea, Essex
User status: Offline
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I'm gonna take sump of tomorrow to have a look. If i can't see anything then is suppose the head will have to come off.
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Warren G
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Registered: 14th May 06
Location: Kent
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dont see any need to take the head off
take the sump off - remove the conrod bearing caps to inspect the shells
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corsa bid
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Registered: 4th May 06
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flywheel tight? thats what happened to my bros engine he thought it was fooked once we stripped if found the flywheel bolts werent tight!!!!!!
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Corsa Phil 666
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Registered: 28th Nov 05
Location: Clacton-on-Sea, Essex
User status: Offline
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I torqued them up to the right torque and put locktite on them so i hope it's still tight.
If i take the con rod bearing caps off will i need to replace the ARP bolts or can i still re use them. They were torqued up to 24 lbs (i think) 3 times like the instructions said.
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Corsa Phil 666
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Registered: 28th Nov 05
Location: Clacton-on-Sea, Essex
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Took sump off onlt to find lots of fragments of metal. Pics aren't too clear but theres basically aloud of copper coloured metal with some bits of silver. Also took head off. Pistons look OK. Not much carbon. Haven't taken them out yet so haven't seen rings. What d'ya reckon it could be???
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Warren G
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Registered: 14th May 06
Location: Kent
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arp are surpost to replaced - but id would just reuse em
but you have far more important things to worry about!
going to have to remove the conrods and crankshaft - i suspect something very bad 
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Corsa Phil 666
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Registered: 28th Nov 05
Location: Clacton-on-Sea, Essex
User status: Offline
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Yes i'm just gonna reuse them. Going to take pistons out today. Surely i can leave crankshaft in there. Really don't want to remove it again. I would of thought that it shouldn't crank origntated as it just had reground with all new oversized bearings. Suppose wait and see what i find today.
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Corsa Phil 666
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Registered: 28th Nov 05
Location: Clacton-on-Sea, Essex
User status: Offline
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Rings are all ok and big ends are all ok. Some wear marks on big ends but they have been in almost 900 miles now. Just thought i bought the block bored out but had the tip of the crankshaft snapped (pulley end) where it had been in a crash. Is there a possibilty that the block is bent or mis-shapen?? I have a spare block at work so it wouldn't matter if it is. Although it may have damaged the bearings. What do you reckon? Is it worth taking out this engine and inspecting everything and putting into my other block after it's been re-bored??
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Corsa Phil 666
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Registered: 28th Nov 05
Location: Clacton-on-Sea, Essex
User status: Offline
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Also when i put the engine all toghter it was very tight to turn over by hand but now its alright as the bearings have worn in. Do you reckon it was so tight because the block could be deformed? Sorry about the essay!
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Warren G
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Registered: 14th May 06
Location: Kent
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with that amount of particles there is some thing very wrong
as long as the sheels aint scored there ok, best to take the crankout
measure all the shells and journals - i have tolance figures if needed
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Corsa Phil 666
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Registered: 28th Nov 05
Location: Clacton-on-Sea, Essex
User status: Offline
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Yes if you can please give me all the tolerances i will check them. Do you think it's worth trying my other block? I will have to check the mains but the big ends are all ok. I hope the crank aint buggered!
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Corsa Phil 666
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Registered: 28th Nov 05
Location: Clacton-on-Sea, Essex
User status: Offline
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Took engine out today. The centre main bearing (the one with the wings) has been spinning in it's seat. Just spoke to the bloke who reground my crank and he reckons the crank is totalled. Do you know if a 1.4 16v crank is the same? Seeing as i have one laying around.
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Warren G
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Registered: 14th May 06
Location: Kent
User status: Offline
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the 1400 has a different stroke - so pretty sure its different
i have a x16xe crank - where abouts are you?
and did the bloke say why its fuked? prob bad regrind/or wrong size shells
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Corsa Phil 666
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Registered: 28th Nov 05
Location: Clacton-on-Sea, Essex
User status: Offline
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I'm in clacton on sea, essex. No nothing wrong with regrind. Just when i was fitting it, it was tight whereas he said it should have been able to turn quite easy. He said sometimes you have to 'take a bit off' sometimes? Anyway it fu**ed because the shells spinning have turnt the crank a weird colour. Also it starved oil to one big end so that melted as well.
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Corsa Phil 666
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Registered: 28th Nov 05
Location: Clacton-on-Sea, Essex
User status: Offline
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I may have sourced a crank but i'm waiting on a phone call. If i can't get one how much would you want for your one. It'll be reground if it needs it. Lightened and balanced again and i'm getting him to fit it.
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Warren G
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Registered: 14th May 06
Location: Kent
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quite heavy, so idealy wanted picked up - £20
but does it realy needed to be lightened and balanced???
there pretty good anyway
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csweatherston
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Registered: 16th Jan 06
Location: Devon
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the cranks damaged that bad?....oh dear....
to be totally honest mate, you wont see much difference with a lightened/ balanced crank anyways.
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Corsa Phil 666
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Registered: 28th Nov 05
Location: Clacton-on-Sea, Essex
User status: Offline
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Yeah and one conrod is buggered aswell. Gone totally black. I may have that crank as my friend needs to pick up a door round your way warren.g. I'll let you know.
With the lightening and balancing it's just nice to know it's done sort of thing. Prob no gains but piece of mind.
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Jas
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Registered: 13th Oct 04
Location: Mid Wales
User status: Offline
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haven't read it all, but knocking at right could be crank.... when its cold it wont be as bad, but when its warm and the oils thin its knocks like a...ermmm... hammer 
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