Probably doing a first start tomorrow. Hope it works. (Cracked cylinder head) Topic is solved

[dikidera]

So tomorrow we will attempt to start my 2.4i S60. Unfortunately chances of it being problem free are rather slim, because of a few key details.

• Small warpage on the block, 0.05mm or 0.002 thou on Cylinders 1 and 2,on the side of the cylinder(s) closest to the exhaust side. Which is maybe not coincidentally, where I had the low compression because of the bad head gasket. The head was machined 0.14mm

• Because of waiting too long, Cylinders 1 and 2 had corrosion of the inside of the liner which resulted in deep pits(relative to what is considered deep for an engine), which may or may not causes issues later on.

• Because of sloppyness and the person helping me being very impatient we slapped on the head before ensuring the head surface was clean and free of any dirt or particles.

• Upon reinstallation of the camshafts and later on cam cover, the exhaust camshaft was installed 180 degrees out of phase, which caused an audible cracking sound on the right side of the cam cover as I was rotating the cam cover tool. At first I noticed the right side had fully sealed before the left side of the cam cover, even though I was rotating both tools evenly. And it is after torquing down the cam cover did we notice the exhaust camshaft being 180 degrees out of phase. We sorted this out. We found no visible cracks to the cam cover but it is still possible for it to have cracked. So far so good.

. Nope cracked head from this stupid mistake.

In any case, even if the engine is scrap and doesn't end up working, the car needs to be fully assembled if I am to have a shop replace the engine for me.

And if it works, it will be a miracle.

[vtl]

Yeah, rush is a bad helper here. I took it slowly, did almost a full engine rebuild (crank bearings are factory) in 2 months working mostly at nights. Never worked tired, paid a lot of attention to everything. It still works.

[matthew1]

Background for people picking this up fresh: viewtopic.php?t=102460






Edit: crossing my fingers for you!

[dikidera]

We will be cranking tomorrow. I just hope I nailed the position of the electrical wiring.

[dikidera]

Car started more or less fine. I have installed a brand new PCV and brand new hose. However there are indeed more exhaust gasses passing by the rings for sure.

However...after waiting for the car to idle to working temperature and giving it a very slight push to the gas pedal there is a noise coming from the harmonic balancer or inside the crankcase as if I've dropped a nut or bolt inside. Which could've realistically happened

Also brand new tensioner of the timing belt but not sure if the play is normal.

[vtl]

The play is normal.

[dikidera]

And the rattling. I wonder if I can process the video to bring out the rattling noise.

[BlackBart]

I hear a little rattle, but it doesn’t sound like it’s every rotation.

[dikidera]

I tried to isolate the frequencies in Audacity. Is it more clear now?



I can only describe it as a nut or bolt rattling. I am almost convinced that is what it is, after 4 or 5 months with no cylinder head, who knows if something fell inside via the oil return passages on the engine block. It could be the harmonic balancer, although the car did not exhibit such rattling before.
It could be the tensioner, I was unable to set the tension properly.

I was advised to remove the harmonic balancer and try to see if the rattling is there. Although I am not sure if running the engine for a short period of time will hurt it or not like that.

You are right, it's not every rotation for sure. I mean every second the crankshaft has done many rotations, it could be something related to the harmonic balancer or the tensioner.

[jonesg]

could be almost any moving part, a stethoscope might help track it down.