4AGZE rebuild worklog

[TERRA Operative]

I just smeared the oil pump with assembly grease (along with every other moving part in the engine) then turned the engine over with the coil and fuel pump disconnected to build pressure before I started the engine.
A quick peek into the cam cover to make sure oil was making it up there, then the engine was started.

Worked fine for me.

[quiksilv]

Yea I see what you mean now, probably don't have it in the right place do I. Smeared out when I put the cap on though so should still be ok

[quiksilv]

Did some more over the weekend.

Fixed up the cam cover sealant (cheers cuzzo)


Harmonic balancer required some cutting of the timing cover plastic



The end of the CAS shaft required grinding in order to clear the head stud


Water pipes and alternator installed. New knock sensor and temp sensors.


Power steering bracket and air conditioning bracket installed. Also water drain cock and -3an nipple for turbo oil feed.


Front shot. Unfortunately my torque wrench only goes to 100Nm which is a bit of a distance from the 137Nm required by the harmonic balancer bolt. Will fix it up later.

[dangdang]

Did "some" ACE

[Casey-G]

Very interesting about the end of the CAS shaft with the ARP studs, I didnt have a problem with this :S maybe i should check it? I know my head is a bigport n all but that side of the motor should be identical to a smallport.


Anyone else had this issue?

+ awesome work, you get things done very quickly

[mookschank]

Nah my bigport & CAS & ARP clearance was fine...

[dangdang]

Mine is good but I have read of others having the same issue.

[quiksilv]

It's stalled for way too long so need to finish it before I lose motivation! Getting harder the closer to christmas too.

I had heard of the CAS problem and lo and behold I had the same issue. Would rather grind down the shaft than the stud itself though.

[Cuzzo]

Very interesting about the end of the CAS shaft with the ARP studs, I didnt have a problem with this :S maybe i should check it? I know my head is a bigport n all but that side of the motor should be identical to a smallport.


Anyone else had this issue?

+ awesome work, you get things done very quickly

i had this problem. fixed the same way...nice work.

Is that a factory harmoic balancer? Have you had the crank balanced with it?

[quiksilv]

It's all aluminium which I know doesn't have the rubber part (as does the stock balancer?) but its been balanced along with the crank, clutch, flywheel etc. - unsure if it was balanced together or most probably separately.

[allencr]

It's all aluminium

Right so it's just a pully, nothing more, and for balance it would be very difficult to make one that was out of balance, just get it tight!

[quiksilv]

Ahh yep I see your point, cheers!

[PrettyCoolWagon]

Nice rebuild mate, shame about the first engine, you live you learn, I have my first 4agze sitting out the back shed with more baked on oil than yours. the engine has 85k on it & has sat idle for 10years After seeing your piston head, I know I have to strip mine all down.

What car is this going into?

[quiksilv]

Thanks. Here is the victim, my AE92 GTI.



goneski

[dangdang]

Lovely, I like fwd victim car donors