Oh fun! Spun rod bearings!

[Tachyon]

Man... I am not having a good week...

I just finished building another 2.4:

Everything was cleaned and machined to my specifications by Gosh.
Crank was balanced and polished.
Custom pistons had the PWC I wanted.
I ground the rings for my usual end gap.
Valve clearance was clayed and several thousands better than I required.
Correct clearances (plastiguage) for main and rod bearings, correct side clearances (feeler guage).
Graphite Moly used on the bearing surfaces, 20w 50 dino on the rest.
PermaTorque headgasket with A1 studs torque to 100lbs with moly in 6 stages.
OEM 2.4 cam gears (no degreeing required) and timing belt, alignment and tensioner gap was correct after spinning, waiting a hour and respinning.
Primed oil pump with grease.
Everything spun nice and smooth.
Filled the engine with straight 30w dino oil for break-in.

Fired the car up, verified oil flow at the head.
Let car warm up to 200 degrees.

Took it out and began to break in the rings. I was taking it up to ~12 psi, at 4 to 5000 RPM and then engine breaking in a low gear. Car felt really strong. After about 5 minutes of this I was approaching a T intersection and popped the clutch in and proceeded to coast the last 200 feet. It was at this point that the unmistakeable sound of rod knock started. Very quietly at first but rapidly increased in noise when suddenly I heard a sick metallic screech and the motor seized. Thick black smoke was everywhere, pouring out of the head evac.

Flash forward to last night. I removed the oil pan to get a better look. Behold the carnage:

http://www.beyondmechanics.com/carnage/4.jpg

Look at the heat discoloration!

http://www.beyondmechanics.com/carnage/5.jpg

The crank is just FUBAR...

http://www.beyondmechanics.com/carnage/6.jpg


This is the shot that really scares me, because it appears that for some reason the bearing was not getting oil. looking up the journal it appears to be dry.

http://www.beyondmechanics.com/carnage/7.jpg


I've only built a handful of 4G engines, so I am most certiantly not an expert. Still, does this seem rather odd? I am trying to figure out what I did wrong on this engine or if it was a clogged oil journal in the crank or block?

Anybody have a similar situation with a freshly rebuilt engine?

[scheides]

Wow, week of carnage. Sorry dude :( Thanks for the awesome pics though, hopefully you get to the root of the problem!

[Matt D.]

Did you prime the engine before starting it?

[Super Bleeder!!]

Wow, it seems like you knew what you were doing. I suppose you should pop the freeze plugs out of the oil galleys and take a look.

Also perhaps the oil galleys in the crank itself are clogged.

[asshanson]

Are they all spun or just that one? Definitely looks oil starved, very dry in the crank by the looks of it.

[Tachyon]

Did you prime the engine before starting it?

I turned it by hand a few times, but did have quite a bit of lube in the oil pump housing. The funny thing is there was oil flow to the head, which is the last place the oil visits before returning to the pan.

I think I'll have to inspect the crank journals before installing the next crank. Live and learn I guess...

Asshanson, I've not yet verified if more than one spun. You can see oil coming out of 2 of the other rod bearings, but nothing on 4. If both 2 and 4 spun it really makes no sense because the oil galleries I believe are different to both bearings.

[Tachyon]

Ok, here is the oil diagram for the 2.0, which should be the same as the 2.4, 6-bolt.

http://www.beyondmechanics.com/dsmoil.jpg

If this is correct, the the problem almost has to exclusively lie in the crank since at least two of the rods were getting oil, the mains are fine and there is oil to the head. I guess the next step is yank it all out (again) and inspect everything.

[Kevin 1G Drummer]

Wow, that sucks. My guess is that the oil galley in the crank was plugged up, Thus,m starving that bearing of oil.

[blackrosenova400]

You should call me, I work in Savage, Id like to come see if after I get off of work at midnight.

612-221-0778

Chad

[blackrosenova400]

I hate to break it to ya but that indicates a misinstalled main bearing. Let us know what you make of it!