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Old 05-06-2011, 12:18 PM   #1
paxfam1
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Default 01 1.9 dohc rebuild failed?

Hello everyone,

01 sl2 came into shop other day customer complaint of excessive oil burning. We diagnosed, clogged oil control rings, and valve guides excessivly worn.

Head was sent out for rebuild, done by a very reputible machince shop.

All rod bearing and main bearing that were in the motor, shown very little wear to them at all and there was still cross hatch on cylinder walls, it appears to be a well maintained engine.

So we put new head on, new rod bearings, all new gaskets, ect ect.......and a very good cleaning.


After the engine was fully assembled engine ran great it idled in the stall for around hour or two. Then I took it out on the road and drove it, put about 5 miles and cam back to the shop because I was starting to develop a small tick/knock (NOT GOOD) It was being starved for oil for some reason.

Gauge on the car when engine was cold at start up it had about 40-45lbs of oil pressure, and the pressure dropped as it reached full temp. When it got to full temp the pressure was down to around 5lbs. Ok so now oil light is starting to come on, and now we have a all out knock in the engine.

Pulled oil pan back off, and found that the sump screen was clogged with what appears to be some sort of cloth material, looks like head gasket material. I had one chunk of it that was size of a quarter and the rest was just mushy debris.

Pulled off rod caps and found that each one has groovs in the bearings, that you can catch your finger nail in, may be 10 thousands at most, and same on crank it self.

Opened up filter and it had tons of that **** in it to, but nothing to unusual I guess. Oil that was drained out was really a gray color about the color of that gasket material.

My big questions are, is it head gasket material, seems like there would have to be alot of it to change color of oil, and could that debris actually hurt the bearings, they are grooved, but not over heated by any means?

So how do I figure out where it came from, and how do I get it all out of the block, I would prefer not to take head back off if I can help it?

Ideas?

Thanks in advanced, Mike

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Old 05-06-2011, 12:31 PM   #2
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Default Re: 01 1.9 dohc rebuild failed?

Did you use a DOHC gasket? Of course, the top deck of the block is the same, but the DOHC head has some passage in it that the SOHC doesn't. And thus the head gaskets are different. IIRC, the SOHC gasket is solid in one place where the DOHC gasket has an opening. Just a US-WAG (un-scientific wild....), but perhaps that part that's different somehow got pushed out by the oil pressure (I wanna say it's an oil passage that's different) and let loose into the crankcase.

Somewhere in the photo gallery is a set of pics showing the difference. Someone had used the wrong gasket on a rebuild; I forget what the outcome was, but the difference between the gaskets was very clear. Again, this is pure speculation.

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Old 05-06-2011, 01:56 PM   #3
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Default Re: 01 1.9 dohc rebuild failed?

The head gasket was out of a dohc head set, I guess I never eyed the two gaskets up, but I doubt that a sohc gasket got stuck in there?

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Old 05-06-2011, 03:41 PM   #4
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Default Re: 01 1.9 dohc rebuild failed?

The head gasket is a Kevlar composite so test the fiber and see if it is Kevlar. The material in the pan is what I would be interested in though. If the material got into the oil gallery downstream of the filter than the filter failed or bypassed and that is another issue. I wonder if you are looking at a shop towel that ended up in the timing chain area. The gray is probably bearing metal and possibly piston.

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Old 05-08-2011, 06:53 PM   #5
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Default Re: 01 1.9 dohc rebuild failed?

So the largest peice of that material I could find, I did identify it as a shop towel. So I guess my next question is, could that soft material actually scratch the bearings/crank I would think not?

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Old 05-08-2011, 07:13 PM   #6
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Default Re: 01 1.9 dohc rebuild failed?

No, buy it will definitely plug up the oil galleries in the block, chain tensioner, crank, and head. The oil pump is full of that stuff also. Cotton/polyester is quite tough and it will score the bearing slightly though. The biggest trick will to get it all out of everything. If it was a paper towel then think of it as a ground up 2X4 and that will gouge bearings.

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Old 05-08-2011, 07:52 PM   #7
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Default Re: 01 1.9 dohc rebuild failed?

Yea, it was paper towel, I guess that makes since, I cant find anything else in the engine that could have done it?

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Old 05-08-2011, 08:50 PM   #8
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Default Re: 01 1.9 dohc rebuild failed?

Yes, paper goes all over. I would be most concerned about how to get it all back out of the head oil gallery that feeds the lifters.

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