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Underbody braces, turbos and more!

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PostPosted: Wed Nov 12, 2014 7:18 am 
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Well guys... I figured there aren't enough blurry photos of a GTI engine online so i thought i might help out. I recently managed to get really lucky and get my hands on a pair of old DOHC engines that have literally been sitting in the dirt in someones shed for much too long and not a little bit too soon either. My engine is getting on in years and is slowly but surely dyeing on me due to soo many miles and the abuse of a previous owner. No matter how well it treat the little guy i'm fighting a loosing battle. anyway picture time...

Here Is my Precious Little Blue Beast In all its Dusty Dirty Glory
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And here is what, with a little work and lots of time, money, and fair bit of luck will eventually be the new little blue beast
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File comment: And here is what, with a little work and lots of time, money, and fair bit of luck will eventually be the new little blue beast
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the teardown is going well, got a nice mess to show for it
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Stinking pick-n-pull has to write on everything, and the paint even looks in good condition, what a shame
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took me for flipping ever to tape up mine and paint it and it still didn't come out perfect
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File comment: took me for flipping ever to tape up mine and paint it and it still didn't come out perfect
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My shop mascot Prongs is pleased with the progress
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OFF WITH ITS HEAD.... Definatly using tools the OSHA Approved way
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Well that didn't go so well, maybe not OSHA approved after all, that or prongs is demanding a blood tribute for working in his shop
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File comment: Well that didn't go so well, maybe not OSHA approved after all, that or prongs is demanding a blood tribute for working in his shop
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they make it look so easy in the book, just use an 8mm allen key and adapter and pull those head bolts right out
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File comment: they make it look so easy in the book, just use an 8mm allen key and adapter and pull those head bolts right out
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Well i tried it the way the book shows or at least as close as i could replicate and after destroying an allen wrench and four sockets i had 9 of the 10 headbolts out
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File comment: Well i tried it the way the book shows or at least as close as i could replicate and after destroying an allen wrench and four sockets i had 9 of the 10 headbolts out
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running out of 8mm and 5/16 sockets
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total death toll 4 craftsman sockets and a good allen wrench and there is still one blasted bolt stuck in the head, gotta get more sockets tomorrow
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File comment: total death toll 4 craftsman sockets and a good allen wrench and there is still one blasted bolt stuck in the head, gotta get more sockets tomorrow
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Well Gonna have to call it a night and worry about that last headbolt in the morning, Dont know if anyone will be interested in seeing my attempts at a rebuild but if anyone is let me know and i'll keep the thread updated, might do it anyway out of spite. also if anyone has any questions, comments, advice, and or any criticism please leave a comment i could probably use some outside input.

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PostPosted: Wed Nov 12, 2014 8:55 pm 
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I wont comment just say thanks for posting I subscribe to this thread..jv&s


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PostPosted: Wed Nov 12, 2014 9:42 pm 
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You do realize you can unbolt your nicely painted intake plate and bolt it onto the engine your building right?

Anyway, good luck with the build. Parts are still available to rebuild these and don't be shy about asking questions if you have any.

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PostPosted: Wed Nov 12, 2014 11:25 pm 
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I'm also just chiming in because this is a task I plan to approach exactly the same way--if I can ever find a used lump to rebuild.

Anyway, I appreciate the pictures and will also be following along. 8)

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PostPosted: Fri Nov 14, 2014 12:27 am 
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I'm glad its not just me that has issues with these headbolts.... I've had the best luck with a dedicated hex socket and an impact for removal.

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PostPosted: Fri Nov 14, 2014 3:33 am 
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Thanks for the chuckles. Keep up the good posts.

Try a little fine cut polish on the paint marker on the intake.


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PostPosted: Fri Nov 14, 2014 4:51 am 
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Well i broke down and bought a set of allen or hex head sockets and managed to get the last headbolt out, and after a little persuasion with a deadblow i finally got the head off and found a few interesting things i could use a second opinion on. First i might mention before i got down to the head i noticed a couple things that seemed to be good signs, either of low overall mileage or of someone who took care of their car. One thing that stood out was it had what looked to be a barely used OEM Suzuki timing belt and a new looking tensioner and underneath the dirt and corrosion nothing looked too badly worn, at least on the outside. After pulling the valve cover the top end looked quite clean in spite of sitting in the dirt for the past 10 years and the cams and lifters had no obvious issues or signs of wear, good news thus far. After pulling the head there was conflicting evidence that makes me suspect this might have been a older engine that had been rebuilt before for some reason ending up in the scrap yard with little mileage on the new engine but that's just a theory

At first glance it looks pretty nasty but the only thing that really concerns me is how badly the water jackets were corroded. I also quickly noticed that under a little carbon the pistons looked pretty good and the cylinder walls still have obvious crosshatch honing marks and next to no wear. From both the good and bad together i thought maybe it had been rebuilt however, though I have torn apart and rebuilt a number engines before, i haven't worked on anything that has been sitting for quite this long in such conditions so perhaps just time and an improper PH balance has corroded away the aluminum this way. Maybe a few of you with a little more knowledge on these engines can give me your opinions on the condition of the engine and whether or not i should even attempt rebuilding this block or or find a spare and swap the internals, perhaps a final decision will have to wait till i can get the bottom end apart. Anyway here's more Photos

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Some nasty looking pitting and corrosion in the next couple pics

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Any Ideas on how best to clean all this junk and corrosion residue out of the jackets and crevices in the block?

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Cleans up pretty nice but those jagged edges bug me, BTW can anyone who knows tell me if these pistons look like OEM or aftermarket, i don't know the engine well enough to tell at first glance.

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Aluminum Wheel cleaner seems to work ok for cleanup but its taking forever, Suggestions?

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Listen to thine engine and mind thine tach, lest thine whirlybits seek communion with the sun.

1989 Suzuki Swift GTi, A work in progress as always.


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PostPosted: Fri Nov 14, 2014 4:37 pm 
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That Cam looks like very low use....wow

How were the oil ring glands & drain holes
looks like that motor ran along time without any anti corrosive fulids (antifreeze)
short of boiling out that block....
preston has a cleaner when you get it back together you run it diluted in water but it's so-so at best
.

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.
Image

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t3 ragtop wrote:
the 3 banger isn't at all a "grenade." it's a tough little son of a bitch doing a big job. respect it.
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PostPosted: Fri Nov 14, 2014 5:09 pm 
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The pitting can be a concern if it is close to the cylinder edge and if there is any in the head I would be more concerned since these can lead to cracks.

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PostPosted: Fri Nov 14, 2014 11:42 pm 
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I've been gone for a very long time. Subscribed for sure...another pair over here and I need to do pretty much the same.


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PostPosted: Sat Nov 15, 2014 11:02 am 
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That C2 on the piston looks like a Suzuki marking for the size.

Ken............


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PostPosted: Sat Nov 15, 2014 9:54 pm 
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Got the bottom end apart this afternoon and other than noticing a little end-play in the crank it all went well and looks good. I imagine there is a spec somewhere for crank end-play or for the distance between the thrust washer/bearing surfaces on the crank but until i can find it and dig out my measuring stuff i'll let that slip down a little on my list of priorities. Went and talked to my local machinist about how best to clean up the block and what to do about the corrosion and we came to the decision to first throw the block in their industrial parts washer and go from there depending on what the end result looks like. I was also thinking i might begin tearing apart the other spare engine i have and see what it looks like, perhaps i will be a little luckier with this block than the last. As i said everything looked pretty good as i was pulling the crankcase apart but i will post photos later tonight so you all can see if i missed anything in my haste to get it done.

BTW i have asked a few people already their opinions on parts but i'll ask again here. i have a few sources in mind already but does anyone here have a favored place to get quality engine parts hopefully OE spec or better. I'm not looking to build a "race car" but i want the best quality strong & reliable parts i can afford, so, if you were building a NA GTI with moderate improvements, Chipped ECU, polished ported head & 3 tech Cams, 2" cat back, etc, where would you source your engine parts?

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PostPosted: Mon Nov 17, 2014 6:51 pm 
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Just a bit of rust

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Pistons look ok though

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And that Gentlemen, Is an engine.

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Listen to thine engine and mind thine tach, lest thine whirlybits seek communion with the sun.

1989 Suzuki Swift GTi, A work in progress as always.


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PostPosted: Thu Nov 20, 2014 3:58 am 
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Been Disassembling my other spare engine and this block seems ok, no real corrosion or pitting in the water jackets so i have one good block at least. Dropped them off them both to be cleaned today so i will see how they came out tomorrow. I've also been considering media blasting all the rough edges on the first block and tig welding in a little filler in all the low spots then have my machinist mill it back down flush again. Haven't seen allot of activity on the thread lately but if anyone is still keeping tabs and want to see the progress i will continue to post new pics and updates.

A forum is and awesome place for us all to learn and share knowledge and experiences so as someone new to the Suzuki / GTI following it kinda sucks to see so little activity. It seems like i missed the boat even though i just got started, maybe its just me but it feels lonely on here and it really sucks especially since i can use all the help and advice i can get. I hope there are a few of you out there passionate enough about our little world to stick around the forum and occasionally give advice to the noob asking stupid questions. Anyway Enough of my flowery wistful talk my point is i hope somebody is still watching and i'm not wasting my damn time posting and asking questions when no one is there.

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Listen to thine engine and mind thine tach, lest thine whirlybits seek communion with the sun.

1989 Suzuki Swift GTi, A work in progress as always.


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PostPosted: Thu Nov 20, 2014 7:59 am 
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Keep it going there is always some one watching.Good luck with the blocks after the cleaning. I got 2 like that but was very lucky no pitting or rust.

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PostPosted: Thu Nov 20, 2014 4:32 pm 
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OH believe me there are a lot of people watching this thread.. I check it everytime I log in to see if there are any updates. Not because I am planning on doing what you are doing because I have already done it, I check the thread to see if there is any new questions or progress.

I would avoid the welding of the block to fill in the pits. The heating and cooling of the block will most likely cause those welds to break and then you may end up with little bits moving around your engine. If you have a good block just proceed with it and use the other one as a boat anchor.

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PostPosted: Thu Nov 20, 2014 4:56 pm 
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Your motors weren't purchased from "Electro" were they?

http://www.teamswift.net/viewtopic.php?f=15&t=58907

Just checking--I had sort of hammered out a deal for one of them to pick up over Thanksgiving, but then he sent an email that, sorry, he'd sold them all :(

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PostPosted: Thu Nov 20, 2014 4:58 pm 
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TheINCRide wrote:
OH believe me there are a lot of people watching this thread.. I check it everytime I log in to see if there are any updates. Not because I am planning on doing what you are doing because I have already done it, I check the thread to see if there is any new questions or progress.

I would avoid the welding of the block to fill in the pits. The heating and cooling of the block will most likely cause those welds to break and then you may end up with little bits moving around your engine. If you have a good block just proceed with it and use the other one as a boat anchor.

THAT... Somehow there was a piece of metal (looked like a bolt) somewhere in the block that got stuck in the waterhousing and caused the new pump to fail after just a few months.. Had to replace it again.

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PostPosted: Thu Nov 20, 2014 4:59 pm 
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you can tell how many views your thread has by opening the section index page.

there are a bunch of people watching your thread. don't feel as if you are wasting time and effort because all of your project postings are added to the archival data. it all counts towards the already excellent knowledge base found here on teamswift.

we love pics. we pour over pics.

but you are right, the traffic here has slowed. our cars are getting older and there are fewer left. it doesn't make the lunatic fringe love them any less. :wink:

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PostPosted: Thu Nov 20, 2014 5:52 pm 
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I personally would not use that block seeing all the corrosion it has but I also have like 5 of these motors so lots of options and can afford to be fussy! oh and keep this thread going!! I am lovin all the pictures!!

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PostPosted: Fri Nov 21, 2014 12:24 am 
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Mile High Racing wrote:
I personally would not use that block seeing all the corrosion it has but I also have like 5 of these motors so lots of options and can afford to be fussy! oh and keep this thread going!! I am lovin all the pictures!!

.
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PostPosted: Wed Nov 26, 2014 11:39 pm 
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i have started rebuilding a 93 swift gt and found it can be run into alot of money .. i will need help cause i want to tubo mine will get pics up soon


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PostPosted: Thu Nov 27, 2014 12:22 am 
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dknight1973 wrote:
i have started rebuilding a 93 swift gt and found it can be run into alot of money .. i will need help cause i want to tubo mine will get pics up soon


Awsome post pictures

Question: Why turbo.?

there is a memeber right now that has a turbo for sale that would be perfect for a DOHC
The N/A G13B DOHC is not to pricey to build.!

DOHC get spendy if you boost them if you want it to be reliable
you'll need a Beefer Gear box that another member can build for you with hefty parts in it that is documented to hold up
.....jv&s
.

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t3 ragtop wrote:
the 3 banger isn't at all a "grenade." it's a tough little son of a bitch doing a big job. respect it.
suprf1y wrote:
I didn't save anything.Vehicles are to me, like little boys are to Tommy.Toys to be abused for my own personal pleasure.
jrjd wrote:
"Driving a Swift GTi is like driving a bike in your house".


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PostPosted: Thu Nov 27, 2014 4:04 am 
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want to make 280- 300 hp ... what kind of setup do I have to have ? I am a pretty good with cars but never built or turbo one.. is there any books that yall know is good to help?


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PostPosted: Tue Jan 06, 2015 1:28 am 
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Well.... My apologies folks, it would seem i'm quite the hypocrite, yammering on about low activity both on the thread and the forum in general the promptly disappearing without a word for a month and a half. I certainly haven't much room to talk on the matter of a lack of presence. Anyway i hope at least a few of you will still find some interest in my newly continued thread as i will be attempting to keep up my end with the posting and all, i just got a little sidetracked on a few other projects over the holidays as you will see in the photos to soon be posted.

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