engine hydro-locked....rebuild or replace

[Jbird]

I thought I'd start a thread about my hydro-locked engine and it's repair or replacement. I'll try to update the thread as I find out the extent of the damage and then the solution.

Right now, i'm thinking it's just a bent rod on cylinder 2. The samurai has been cleaned and turned around in the garage so I can work on it easier. I'm hoping to drop the oil pan in the next day or so. I should be able to get a look at the rods and have some idea of the damage.

Update to follow in a few days.....

[sungoesdown]

did you get the link to the craigslist ad i posted about the 16v low mile motor?

[Four_Play]

What makes you think its a bent rod?

[Jbird]

What makes you think its a bent rod?

It's only running on 3 cylinders and making the klacking noise that sounds like a bent rod. :smile:

And when an engine takes in water, generally a bent rod is the outcome.

[Jbird]

Well I was wrong....it's not a bent rod on #2






It was a bent rod on #4
Hard to see in this picture but it's tweeked!
http://www.coastalcarolinaoffroad.com/gallery/files/5/8/hpim1664_thumb.jpg (http://www.coastalcarolinaoffroad.com/gallery/showimage.php?i=118&c=3)

My plan is to leave the engine in the Samurai. Pull the head. Pull the bad rod and piston. Replace just the bent rod. The engine looks pretty clean.

[Beachjeep]

So is this going to be a fairly cheap repair? Do you need someone to hold a flashlight.

[enigmaverse]

or someone to stand around and hold a beer?
:cheers2:

[NCJeepin]

That doesn't sound like bad news at all.. be sure to keep the cylinders oiled down while she sits.. Let us know if we can help..

[Jbird]

So is this going to be a fairly cheap repair? Do you need someone to hold a flashlight.

It will still end up costing several hundred $.
I'll put all new seals in the front of the engine. New timing belt and water pump. New headgasket and the cost to have the head cleaned up. May go ahead and re-ring all the piston.

But it's looking better than I first thought. But I'll know more once I pull the head.

It may be after Christmas before I can do the repairs. I want to get it all apart to check for damage. Then I'll know what parts to save for and order.

[Razorrodent]

It will still end up costing several hundred $.
I'll put all new seals in the front of the engine. New timing belt and water pump. New headgasket and the cost to have the head cleaned up. May go ahead and re-ring all the piston.

But it's looking better than I first thought. But I'll know more once I pull the head.

It may be after Christmas before I can do the repairs. I want to get it all apart to check for damage. Then I'll know what parts to save for and order.

Well you know to just let me know when your ready or need any help with it. Least i have those spare rods.

I really need to order a set of the seals for dads tracker.... Actually i really need to order the master kit for it and rebuild it too.

[creepinjeepin]

theres an old body shot suk in the storage place in my buddies neighborhood, i looked at the engine and its still there.
not sure if theres any problems with it or not.
COULD be something you might wanna look into...

[Bryan]

I was talking to a mechanic @ Sear's Independence Mall one day who has a nice little zuk with a hard top. He swapped ina Geo Tracker motor. Dont recall how much but he said the power gains were substantial and he got power steering and ac as an added bonus. I like the idea of a TDI swap myself. But the Tracker swap I'm sure would be cheaper. :cheers2:

[NCJeepin]

Thats what he has in it currently

[Jbird]

I was talking to a mechanic @ Sear's Independence Mall one day who has a nice little zuk with a hard top. He swapped ina Geo Tracker motor. Dont recall how much but he said the power gains were substantial and he got power steering and ac as an added bonus. I like the idea of a TDI swap myself. But the Tracker swap I'm sure would be cheaper. :cheers2:

Stock samurai 1.3 had about 67hp.
The Geo Tracker/Suzuki Sidekick 1.6 8v has about 90hp.
The Geo Tracker/Suzuki Sidekick 1.6 16v has 95hp.

Doesn't sound like a lot of difference. But seat of the pants is huge. I'm running the 16v and love it.

The TDI is a nice swap, but gearing is critical. Most successful TDI swaps are single purpose vehicles. Either trail rig or Daily driver. It's hard to gear the TDI for both.

[ohv_kj]

I was talking to a mechanic @ Sear's Independence Mall one day who has a nice little zuk with a hard top. He swapped ina Geo Tracker motor. Dont recall how much but he said the power gains were substantial and he got power steering and ac as an added bonus. I like the idea of a TDI swap myself. But the Tracker swap I'm sure would be cheaper. :cheers2:

i know who your talking about...is he there again?? he was going to retire due to his back being messed up...

jaybird how has been the progress??

[Jbird]

jaybird how has been the progress??


I haven't even started repairs yet. With the holidays and everything else I decided to just wait until the first of the year.

So....I hope to get started pulling the engine apart this coming week. I'm going to get the garage cleaned up this weekend so it will be easier to find tools :)

[jeepmkcomin]

jbird did you get my pm?

[Jbird]

jbird did you get my pm?

yes, it said sale was deleted :(

[Jbird]

Started the tear down tonight. I remember now why I don't do engine work. Man I hate working on engines.

I got the intake and exhaust manifolds off. Valve cover is off. Timing belt and everything on the front of the engine is off. Now I just have to remove the head, which is proving to be more difficult than I thought. Head bolts won't budge. :(

I'm done for tonight, continue tomorrow night.

[jeepmkcomin]

jbird that guy relisted... the tracker engine is now at 125$ for the engine and tranny.

[Jbird]

jbird that guy relisted... the tracker engine is now at 125$ for the engine and tranny.


I found the listing. Wrong engine. That's an 8valve 1.6L that he's selling. I need a 16v 1.6L

Thanks for looking out for me though:cheers2:

[Beach Bum]

Sounds like ya got it going on J hope it goes well for ya give me a shout if there is any thing I can do for ya

[Brandon]

Started the tear down tonight. I remember now why I don't do engine work. Man I hate working on engines.

I got the intake and exhaust manifolds off. Valve cover is off. Timing belt and everything on the front of the engine is off. Now I just have to remove the head, which is proving to be more difficult than I thought. Head bolts won't budge. :(

I'm done for tonight, continue tomorrow night.
Have you tried heating the bolts up with a torch then dropped hot candle wax on them? Way better than penetrating oil

[Jbird]

Have you tried heating the bolts up with a torch then dropped hot candle wax on them? Way better than penetrating oil

Penetrating oil on Head Bolts? You're joking right?

Hmmmm.....torch....flame.....oil....FIRE!
No thanks.

:lol:

[Jbird]

The engine is a single over-head cam with 16valves. Kind of a strange set-up. I had to pull the cam to get to all of the head bolts. Went to Dew's and bought the socket I needed.....

got 3 of the bolts to break loose.....

then the socket broke :(

I'm starting to get the sense that this is going to be an interesting project.

[Jbird]

Head is off!

And as far as I can tell....looks like just one bent rod.

So now I will do a little research and find out how much parts cost. While I have it this far apart, it might be wise for me to re-ring the pistons.

I have a lot of work ahead of me. But I'm so glad it's just a bent rod and nothing more.

Think I can straighten it? J/K :)

[buckshot500]

Head is off!

And as far as I can tell....looks like just one bent rod.

So now I will do a little research and find out how much parts cost. While I have it this far apart, it might be wise for me to re-ring the pistons.

I have a lot of work ahead of me. But I'm so glad it's just a bent rod and nothing more.

Think I can straighten it? J/K :)

You should polish it, & hang it from your mirror when you get the time!

[NCJeepin]

yeah thats for sure a keeper for the scrap book

[ohv_kj]

yeah thats for sure a keeper for the scrap book

Mount it w/ the fish...lol

[Jbird]

Most of the replacement parts are in. Now the clean up and re-assembly process will start.

My goal is to be driving it by the end of the month. It's not really that much work. I just have a hard time finding the time.

Anyone have a cylinder hone I can borrow? :)

[Todd]

You gotta let somebody know when you're gonna turn a wrench.

[Jbird]

You gotta let somebody know when you're gonna turn a wrench.

I have all the parts. I even have a cylinder hone. (thanks neal)

But I will be out of town most of the week. :(

I'm hoping to wrench some this weekend. Probably spend Saturday afternoon on it. Then hopefully most of Sunday. Anyone that's wants to come by is welcome to. :smile:

[Jbird]

Re-assembly has begun....

Got the pistons cleaned and re-ringed, honed the cylinders, installed the pistons and rods(with new bearings), installed the head, attached intake and exhaust manifolds.....

Still have a lot to do, but it was nice to finally make a little progress.:cheers2:

[Beach Bum]

Way to go there J sounds like a bunch of progress to me at this rate it will be back on the road soon. Neal:smile:

[Jbird]

Worked on it some tonight. Got the cam in and timing belt on. Distributor is on. Set valve lash. Oil pan is installed and there is 5 quarts of oil and a fresh oil filter.

Things left to do before cranking it up....
Valve cover
plugs
wires and cap
air box and plenum
radiator
fan
coolant
check all connection and bolts

Things left to do before test drive...
flush power steering
refill diffs and t-case

I really want it on the road by Sunday afternoon. Hopefully I'll get time to work on it Saturday and Sunday.

[enigmaverse]

Nice! when we going back to Carolina Backwoods? :dita:

[Jbird]

Nice! when we going back to Carolina Backwoods? :dita:

As soon as I get my snorkel installed :lol:

[Brandon]

Awesome man, you are so close to having that thing up and running

How much has this rebuild cost ya so far?

[Jbird]

Awesome man, you are so close to having that thing up and running

How much has this rebuild cost ya so far?

Haven't added it up....

but somewhere between $500 to $600 total. That's parts and oil and misc stuff. I replaced a few extra things unrelated to the hydro-lock, like the timing belt and waterpump. Once I got it all apart I realized that it needed a ring job anyway. So...if I did everything right and it runs....I'll have a fresh engine. :smile:

[MUD CITY]

Sounds like it will be running in time for gulches:yesnod:

[Jbird]

Well......

Good news bad news.....

First the good news.
Engine is back together and it runs!

The bad news.
The alternator bearings are bad.
But worse.....the clutch is shot! Which really sucks. Now I have to pull the transmission after all. :mad2:

So the Samurai got driven for about 10 minutes today. But now it's back in the garage waiting for more surgery.

[NCJeepin]

well that is good and bad news.. sounds like the hardest is over

[enigmaverse]

that sux.... but I am glad you got the engine back together.

[Jbird]

well that is good and bad news.. sounds like the hardest is over

I guess the water and sand got the better of the clutch. It worked for a little while when I was test driving today. But it was grabbing funny and then eventually got worse.

So the repair list is now.....

Replace clutch
Replace alternator
Replace or clean starter
Fix or replace solenoid on winch
Flush Power steering (still has some water in it after draining and refilling)

I won't be going to Gulches.:(

[GreenFord]

Sounds like my life at times one step forward two steps back....:yesnod:

[Beachjeep]

Well Jay at least the Sami. will be like new when your done.:cheers2:

[Jbird]

Dropped the tranny this morning. Clutch is toast. It's actually missing most of the pads that contact the flywheel. Weird to me how that happened.

Replaced alternator(thanks razor).

So I'll order a clutch Monday and should be up and running next weekend:cheers2:

[Jbird]

Got everything back together and took it for a test drive tonight.
Sounds and runs great.

I'll be nervous about the engine for a few more weeks. I plan on just driving it on short trips until I get my confidence back up. Never rebuilt a motor before.

I still need to flush the power steering and repair the winch. But the Zuk is drivable and back on the road :)

[NCJeepin]

Good news good news!!! Glad to hear it..

[jeepmkcomin]

awesome! Come drive up to wilmington and hang out next thursday night.

[rticul8ion]

How's it holding up thus far Jay