Perkul8r's Rebuild.
 

Well, after posting in the new members area, i decided to get to work on my Laser. For anyone that hasn't read that, I bought car knowing that there may be possible head damage. The previous owner said the car just died one day. So i took it as a project. I have had a few DSM's so its not a new thing to me.

I decided to tear into it the other day and took it down to the timing belt. The belt had the teeth sheared off it on the crank gear. Not good. So I pulled the VC and sure enough, all but one of the exhaust cam rocker arms were sitting in the bottom. So i got tearing into today to see the extent of the damage.

http://i665.photobucket.com/albums/v...r/SAM_0147.jpg
http://i665.photobucket.com/albums/v...r/SAM_0148.jpg

Now my question is. There is definite contact on the pistons. Will i have to replace them? Or can i clean them up and run em.

http://i665.photobucket.com/albums/v...r/SAM_0149.jpg
http://i665.photobucket.com/albums/v...r/SAM_0150.jpg

Re: Perkul8r's Rebuild.
 

If it were me, I would just replace them for peace of mind. Think of it as a good opportunity for 2g pistons I guess.

Re: Perkul8r's Rebuild.
 

My only problem is that i need a car. lol. Me and the gf are down to one car and it aint working out. Plus i dont think i have that kind of money to rebuild a shortblock right now. I understand replacing them, i usually would. Are the 2g pistons that much better?

Re: Perkul8r's Rebuild.
 

Doesn't Steve have some cleaned up 1G pistons for sale on here? Just grab those, some new rings, and do a quick bottle hone on the cylinder walls and there ya go. Obviously the head will need to be repaired/replaced also.

Re: Perkul8r's Rebuild.
 

I already have another head. I was gonna swap it and run it till i have the money to rebuild a shortblock. cause if i am right to swap pistons i would have to do new rod/main bearings.

Re: Perkul8r's Rebuild.
 

Why, do you know that they are bad?

Re: Perkul8r's Rebuild.
 

well, thats what i have always done, i mean dont ya gotta pull the rod caps off and than swap pistons, and than reassemble? But in doing so cant that ruin the bearings? I guess i was always told and was taught that if pulling the rods off the crank to replace the bearings. But hey, maybe there is something i dont know. its happened before. lol

Re: Perkul8r's Rebuild.
 

Mine are .050mm over, I'm guessing he's running stock bore. If your block has been bored out already, my pistons would be the ticket, they include almost brand new rings.

Personally, I'd just clean up your pistons in the car with a dremel, just make sure to cover up the edges so you don't get crap down on top of the rings.

Re: Perkul8r's Rebuild.
 

You said you'd have to replace the rod/main bearings. You're not doing anything that would cause you to do anything regarding the main bearings. And if the rod bearings are in great shape, and you're on as tight of a budget you are making it out to be, then reusing them is simply an option. Me personally, I'd replace the rod bearings while in there for sure because they aren't that much, but you're making it sound like you're broke, so if that's the case then why not consider reusing them (as long as they are in great shape). If they are all scratched up, then replacing them is the obvious answer.

Re: Perkul8r's Rebuild.
 

Like Steve said,
Just smooth out the indents, make sure there are no sharp burrs, and stuff something around the piston and bore to prevent crap from getting in there. I have personally done this on my last car, it was fine.

Re: Perkul8r's Rebuild.
 

Ya, i mean, i am on a budget, i'm not broke, but i would like to have some left over money after getting this running for the family. I did take some time and cleaned up the pistons today. I am also replacing the water pump, idler pulleys, and what not. I want it to last a while. I have found another complete motor that has really high miles on it that i plan on rebuilding.

Re: Perkul8r's Rebuild.
 

So at this point in time my budget has kinda gone out the window. Lol. I was working on getting a new head for the laser when i came across a fairly good deal. A guy here in town was selling and talon and in his add he said he had a tsi with a bad rod and was selling it to. So i emailed him and 24 hrs later i had this:
http://i665.photobucket.com/albums/v...r/SAM_0151.jpg
http://i665.photobucket.com/albums/v...r/SAM_0152.jpg
http://i665.photobucket.com/albums/v...r/SAM_0153.jpg
http://i665.photobucket.com/albums/v...r/SAM_0154.jpg
http://i665.photobucket.com/albums/v...r/SAM_0155.jpg
http://i665.photobucket.com/albums/v...r/SAM_0156.jpg

Re: Perkul8r's Rebuild.
 

That thing looks rough.

Re: Perkul8r's Rebuild.
 

It is. But the parts are good. My only problem is i was all gun hoe to swap the AWD into my laser. But i see that as not an option now that i have looked into. So if there is no major issues with the body car of the talon i am thinking about keeping it together and doing a complete rebuild. I haven't really decided yet though. Mainly depends on the guy with the title or if i can get a title, i bought it as a parts car but asked if there was a way i could get a title. I would really like another AWD galant though too. Decisions decisions.

Re: Perkul8r's Rebuild.
 

Okay, so i got a quick question. I was comparing the motors in my laser and talon, now that i got the head off. Well, the pistons in the Talon are just labeled 63D and the ones in my laser are marked 63D T. So does that mean the motor in the talon is not an actual turbo motor? Also it looks like something happened with the #1 piston. it did hit the head, but ever so slightly. There is only one valve i am really concerned about, it sits in the seal about 90% around, but there is just a little bit that doesn't. Is it ok that I replace that valve? Thanks again.

Re: Perkul8r's Rebuild.
 

63D = Naturally Aspirated
63DT = Turbocharged

Re: Perkul8r's Rebuild.
 

thats what i thought. So if i do use this head, should i swap in my turbo cams?

Re: Perkul8r's Rebuild.
 

So i ordered 2 new valves today, and a spring compressor, couldn't find one here in town. Gonna Switch out the two that may be ever so slightly bent, and than gonna throw in my turbo cams just to be safe. Am hoping to get the head on by friday night. but we'll see.

Re: Perkul8r's Rebuild.
 

You think only 2 valves are bent?

Re: Perkul8r's Rebuild.
 

Only 2 valves had a very little mark on them that looked fresh, And the piston head had some very slight marks in it also. I am also talking about the head off my parts car talon, not the laser head in the pics. I know there are more than 2 bent on that one.

It looks like for some reason the number 1 piston/rod assembly has come apart from the crank. When i pulled the head the number 4 piston is at TDC, the middle 2 are down and i could push the number one piston down by hand. So i am replacing the 2 valves that have the slight marks on them from the number 1 piston. Its the 2 exhaust valves. And i had a local shop check it out and only one valve on that hole doesn't seal all the way. But i was just gonna replace the 2 anyway. I hope that makes sense. Sorry if it dont.

Re: Perkul8r's Rebuild.
 

Got the head together last night, and now its on the car. Timing is set, and hopefully it will be running by Sunday. Still a little worried. But at least this time i had some good manuals to read if i needed anything.

Re: Perkul8r's Rebuild.
 

Its alive!! and it runs great. Was really worried at first, but now its all good. Now i just gotta see why it sometimes grinds going into second when your trying to shift fast. Hopefully maybe just an adjustment. I will be happy as long as its not the trans.

Re: Perkul8r's Rebuild.
 

So i am thinking that the grinding going into second is due to a clutch going out. I was driving along today and when i started pulling up a hill to work i gave it some gas and the rpm's went up but the speed didn't move much. So now i am looking for a clutch. Any you guys have one you like/dislike more than another. I am looking for one thats great DD but can still handle a little abuse at the track.

Re: Perkul8r's Rebuild.
 

Well, seems as how i haven't updated this much. Finally got some things done to the car. Got my wideband hooked up finally. Been hell trying to get into a muffler shop. Did the egr removal and emissions removal, thanks again for everyones help on trying to figure out why i was running lean. Cant believe i forgot that one plug. Also installed some shifter bushings from MAP. Made the shifts feel alot firmer, still need to pick up the right cables for the shifter. And trying to get a fmic and a DSMlink for tuning. Than gotta save up some money, and get some time to get up to DB and get a tune. Thats gonna be a hell of a long drive. Oh well, it will be worth it.