EPAS coloumns are bollox an are renonwed for failing anyway.
Not that it matters as you can still steer with it broke anyway :thumb:
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EPAS coloumns are bollox an are renonwed for failing anyway.
Not that it matters as you can still steer with it broke anyway :thumb:
I missed this, thats a cool looking Meriva right there.
I read up on the common problems on Meriva's before I bought this one.Quote:
Originally Posted by Pete
Common faults seem to be mainly engine related with the Z18XE engine namely the airflow meter, throttle body, coil packs and ECU (which is sat right on the side of the inlet manifold.
I have spare ones in the garage along with the EPAS column just in case.
There does seem to be an issue with the EPAS on some of the cars but I don't think its as common as its made out to be.
Joff
Right more updates....
Due to an ever increasing oil consumption problem it has come to the point where the engine needs replacing with a new one, so...
I sourced a replacement 1.8 16v from a contact in Nottingham and picked it up a couple of months ago. I should of started work on the engine in mid July however due to a reoccuring back problem, I have only now been able to start stripping the engine.....
http://i2.photobucket.com/albums/y15...a/IMG_9197.jpg
http://i2.photobucket.com/albums/y15...Z18xe001-1.jpg
First job was to strip all the cambelt pulleys and associated gubbins off the side of the engine...
http://i2.photobucket.com/albums/y15...a/Z18xe002.jpg
Then it was off with the cylinder head ....
http://i2.photobucket.com/albums/y15...a/Z18xe003.jpg
The bores seem to be in good condition, I will give them a light hone before the pistons with the new rings go back in. Seemed a fair bit of carbon on the piston crowns which will get cleaned up ....
http://i2.photobucket.com/albums/y15...a/Z18xe004.jpg
Next job was to remove the pistons ...
http://i2.photobucket.com/albums/y15...a/Z18xe005.jpg
Had a look at the shells, seemed to be in good order with little wear, they will be replaced anyway as a matter of good practice...
http://i2.photobucket.com/albums/y15...a/Z18xe006.jpg
Got two pistons out before it was time for tea, will remove the other two and the crank shortly.
Plan is to hone the bores, and clean up the block. Rebuild the bottom end with new bearings and oil pump. I'm going to strip the head, clean the inlet and exhaust ports up, remove and clean all the valves up and reseat them in the head and replace all the seals.
I'm cleaning out the lifters rather than replacing them, as at £16 each from Vauxhall I could spend my money better on other things!
Cheers
Joff
Looking like its a good one even though youre replacing everything lol
Hows Paula finding the disastra then :d
She's not happy - says it smells !!! Patrick calls it the silver shed !Quote:
Originally Posted by Spudly
It's my daily from Monday as she's using my Meriva until her's is back on the road ! She's moaning about the fact that the VXR leather seats are "uncomfortable" . She's just got a big bum !
Joff
Lmfao, i hope for your sake she has forgotten her login details and doesnt end up reading that, or you will be sleeping in the silver shed lol
Theres nothing wrong with the disastra anyways, i really like mine, and its just turned 200,000 on the clock last weekend :eek:
http://i8.photobucket.com/albums/a36...4D38F6CA6A.jpg
And still sweet as a nut :d
Hey Spud! I may have forgotten my log in but when Joff leaves his account open and I "just happen" to read it, I think I have the right to reply!?!
Oy husband!!! Not happy with the reference to the size of my backside :cry: Cut it out with the insults! :p
It was a shed, is a shed and always will be a shed. lol That is the truth.
BTW your meriva is so slooooow compared to mine. It accelerates like a donkey and corners like a cardboard box. How long til my car is fixed??? :d
Ha awesome lolQuote:
Originally Posted by joff-turbo-nova
Watch out for the thrusts on the main bearings when you pull the crank out Joff, both of mine have eaten the bearing there, and one had eaten about 1.5mm out of the crank.
Quote:
Originally Posted by joff-turbo-nova
LMFAO, BUSTED Joff, oopsie lol
Will look carefully when the caps come off - cheers :thumb::thumb:Quote:
Originally Posted by MK999
Hahahahahahahaha... +1 for Paula! :thumb::thumb:Quote:
Originally Posted by joff-turbo-nova
Right , pulled the last two pistons out without any issues, then proceeded with the removal of the crank.....Quote:
Originally Posted by MK999
http://i2.photobucket.com/albums/y15...a/Z18XE010.jpg
http://i2.photobucket.com/albums/y15...a/Z18XE011.jpg
All the shells seem in good condition with minimal wear on the thrust bearing which sits under cap number 3 right in the middle of the engine ......
http://i2.photobucket.com/albums/y15...a/Z18XE013.jpg
http://i2.photobucket.com/albums/y15...a/Z18XE014.jpg
No major issues with the crank either....
http://i2.photobucket.com/albums/y15...a/Z18XE012.jpg
I'm taking the block up to my dad's tomorrow to use his honing tool to deglaze the bores and let him cast his +45 years engineering experience over the block , pistons and crank just in case I have missed anything.
Oh and the Z20LET is waiting in the corner ready to jump into my Meriva as soon as this engine is installed and working !
Joff
Pics aren't working but glad your thrust faces are all good :)
Photobucket seems to be having an eppy at the moment - its affecting most of my pics that I have hosted - just noticed the thrust bearing pic has just come up!Quote:
Originally Posted by MK999
Joff
Might just be the clean section but it looks like there might be a little wear on the thrust face of the crank? as long as there's no lip you can feel though, just double check the end float when it's all back together.
hi joff what spary do you use for the lights ? cheers dave
Got the block honed out nicely on Wednesday and then got it back home Thursday and put back on the stand with the engine hoist (very handy item to have!).
Next job was to clean down the block on both sides :-
http://i2.photobucket.com/albums/y15...a/Z18XE019.jpg
http://i2.photobucket.com/albums/y15...a/Z18XE020.jpg
And then give the block it's first coat of engine enamel paint :-
http://i2.photobucket.com/albums/y15...a/Z18XE018.jpg
http://i2.photobucket.com/albums/y15...a/Z18XE021.jpg
Tomorrow the block will get another coat of paint and whilst that's drying I hope to start stripping the head and getting the valves out . May give the ports a bit of a smooth with the die grinder whilst its bare as well !
Joff
Update....
A bit more work today, got the crank cleaned up and put back in with new bearings and then got busy cleaning no4 piston up.....
http://i2.photobucket.com/albums/y15...a/Z18XE028.jpg
Got the new rings on and got the compression tool out and tapped it in ....
http://i2.photobucket.com/albums/y15...a/Z18XE027.jpg
Just need to do the other 3 in the morning . Its very theraputic stripping down pistons , cleaning out all the nooks and crannies and then rebuilding them. Once the pistons are in , its on with the oil pump and pick up pipe and then the sumps going on.
Joff
Cracked on with the engine work today....
Got all 4 pistons cleaned up and new rings and shells installed and put back into the block...
http://i2.photobucket.com/albums/y15...a/Z18XE035.jpg
New GM oil pump was added as well ...
http://i2.photobucket.com/albums/y15...a/Z18XE034.jpg
Cleaned up the pickup pipe as it was rather cruddy and reinstalled with an new o ring....
http://i2.photobucket.com/albums/y15...a/Z18XE033.jpg
Torqued everything down and then put the sump on with some sealant as these engines don't have a sump gasket....
http://i2.photobucket.com/albums/y15...a/Z18XE036.jpg
Next up was starting on the cylinder head , all 16 valves are rather caked with carbon...
http://i2.photobucket.com/albums/y15...a/Z18XE037.jpg
http://i2.photobucket.com/albums/y15...a/Z18XE038.jpg
This was an inlet valve before.....
http://i2.photobucket.com/albums/y15...a/Z18XE039.jpg
And this is after cleaning .....
http://i2.photobucket.com/albums/y15...a/Z18XE040.jpg
Also thought it would be rude not to get the dremmel out and polish out the ports as they seem to have a very rough casing on the inside, I have left it roughish as I understand these engines work better with the inlet rough, will give the exhaust ports a good going over ....
http://i2.photobucket.com/albums/y15...a/Z18XE041.jpg
Need to finish off the polishing with a longer sanding bit.
Enjoy!
Joff
Seriously Joff, you find yourself needing an extra project, ill happily let you rebuild my engine/store my nova over winter, ill hoover up and clean the windows, mow the grass happily in exchange lol
Been busy today...
Finally got the head stripped down ports cleaned out.
Next job was lapping in the valves which is a rather boring job but worth doing to get a good seal on the valve seats.
This is how the valve and the head started , note the nice and shiny ring around the valve and valve seat....
http://i2.photobucket.com/albums/y15...psc395ff36.jpg
http://i2.photobucket.com/albums/y15...ps5aa09ce1.jpg
Once lapped in, there is now a constant "grey" ring, where the faces have been ground together - job sorted only another 15 to do :eek:
http://i2.photobucket.com/albums/y15...ps785a676b.jpg
http://i2.photobucket.com/albums/y15...psfa50f0fc.jpg
The exhaust valves where a bit pitted as you can see here .....
http://i2.photobucket.com/albums/y15...ps8aa65bb3.jpg
But with a little extra work on the lapping process ......
http://i2.photobucket.com/albums/y15...psf0c08602.jpg
Also had to remove two studs which had snapped off into the head. One washer, nut and migwelder later and the problem was solved....
http://i2.photobucket.com/albums/y15...ps413c1a19.jpg
You put the washer over the stud hole and then start welding at the base of the stub, the washer protects the head. Once the weld is at the height of the washer, put the nut on and fill it with weld till it glows cherry red.
With all the heat this put through the stud, you just let things cool to just below red hot and then simply undo. The heat breaks down the crud on the threads making it easy to wind out.
After all the valves were lapped in next job was getting it all back together. 8 exhaust valves fitted....
http://i2.photobucket.com/albums/y15...psdeada7e2.jpg
And then the inlet valves....
http://i2.photobucket.com/albums/y15...psfc578997.jpg
Started on the camshafts and put the inlet one in, notice the cam caps are nice and clean...
http://i2.photobucket.com/albums/y15...ps1705fca4.jpg
These are the exhaust cam caps awaiting a clean....
http://i2.photobucket.com/albums/y15...ps7c5e5762.jpg
Next job tomorrow is get the exhaust cam fitted and then I can put the head on the engine and get the water pump and timing belt stuff fitted.
Joff
Have you marked up/are the cam caps marked? As its pretty important they go back where they came from..
Everything still within tolerance?
Rebuilding engines is indeed therapeutic.I have to agree.
Good work.
They are each numbered like on the C20XE engines which is handy !Quote:
Originally Posted by Andy
End float was good and the gaps on the piston rings was bang on .
Joff
Update...
Got the exhaust cam on and then the head onto the block and torqued down. I was surprised at the tightening sequence, 40nm, 90 ° , 90° , 90° then 45° :eek:. I think the head stretch bolts have now lived up to their name lol
http://i2.photobucket.com/albums/y15...psa4d26a88.jpg
Then got on with getting all the timing gear and water pump back on....
http://i2.photobucket.com/albums/y15...psfe9f3d3f.jpg
1st time round I was a tooth out, but got it on the 2nd attempt!
Then it was on with the covers and I put a set of both inlet and exhaust studs in and placed the gaskets ready for the manifolds.
http://i2.photobucket.com/albums/y15...ps0bb1b972.jpg
http://i2.photobucket.com/albums/y15...psecbba1f4.jpg
Next job is to strip the engine out of the meriva and swap all the bits onto the new block.
Joff
Good work Joff, you dont hang about do ya, i trust the back isnt giving you as much grief now and youre back up to speed?
Nice read Joff, well done. Rebuilding engines is awesome work. As said, very therapeutic! :-)
Looks good... not sure if it's different on what I assume is a Z18XE, but it looks like you might be missing a camshaft sensor? Goes under the top cover between the cams.
Not bad torque on those things too :d not the best I've seen though! BGA MLS gasket on a 106 gti... 80Nm, 90, 90, 90, 90!! I was sweating at the end lol
Yes you are right, this engine came without sensors, will need to swap things over from the other engine sitting in the Merv.Quote:
Originally Posted by MK999
Joff
Right, today's update....
Got on stripping the Meriva, here she is looking a little nervous :(
http://i2.photobucket.com/albums/y15...Z18XE068-1.jpg
After an an hour or so we were getting somewhere :-
http://i2.photobucket.com/albums/y15...a/Z18XE069.jpg
Just after lunch I had it to this stage ....
http://i2.photobucket.com/albums/y15...a/Z18XE070.jpg
http://i2.photobucket.com/albums/y15...a/Z18XE071.jpg
With a large boot full of bits !
http://i2.photobucket.com/albums/y15...a/Z18XE072.jpg
Then things slowed down as I needed to sort fiddly jobs like removing the drive shafts and getting the exhaust removed, both had never been removed so were somewhat difficult.....
http://i2.photobucket.com/albums/y15...a/Z18XE073.jpg
http://i2.photobucket.com/albums/y15...a/Z18XE074.jpg
Noticed that the exhaust is shot from the joint under the cat to the joint at the back box (its all one piece), so that's on the list of parts. Also noted that the sump on the Mervia has a oil sensor in it, the one on the new engine doesn't , so that will need to be unsealed from the block and swapped over once the engine is out.
Engine bed is next on the list to remove, already disconnected the roll bar, bottom ball joints, steering rack and track rod ends.
Just need to disconnect the gear linkage and then remove 4 bolts and its just the engine mounts and the engine is out!
Joff
And I need to clean the new drive!
haha #the wife.
Good progress joff, will give you a ring sometime next week about the flocking
Looking at this picture
http://i2.photobucket.com/albums/y15...psfe9f3d3f.jpg
From memory - the position of the cambelt tensioner looks wrong - the allen key lug is normally at about 20 past !!!
I might be completely wrong but worth checking !!
Dave
Dave,Quote:
Originally Posted by fearless
I lined the pointer up to the 2nd mark for a new belt and that's where I locked off the tensioner - I will be double checking the timing again along with the tension once the engine is ready to be installed.
Cheers for the heads up anyway!
Joff
Quick update....
This arrived this week ....
http://i2.photobucket.com/albums/y15...a/Z18XE075.jpg
An almost new alternator, only been on a vehicle for about a month before it failed its MOT and was scrapped - not bad for £15 off ebay !
More work tomorrow weather permitting - should get the engine out and the necessary bits swapped over.
Joff
joff, get some cardboard from the shop for under that car.....or you'll kill your driveway blocks
Cracked on this morning and got the engine bed removed (4 bolts and it was out !) - notice the cardboard I had in my shed for this job....
http://i2.photobucket.com/albums/y15...a/Z18XE079.jpg
Then I got the engine crane out and got the engine mounts loosened off and dropped the engine out using my new engine leveller I got for my birthday ......
http://i2.photobucket.com/albums/y15...a/Z18XE080.jpg
http://i2.photobucket.com/albums/y15...a/Z18XE081.jpg
I then pulled the engine into the garage and started stripping the parts. The exhaust manifold came off without too many issues.
I was changing over the camshaft sensor when I noticed that the engine mounts were different .....
Astra -
http://i2.photobucket.com/albums/y15...a/Z18XE083.jpg
Meriva -
http://i2.photobucket.com/albums/y15...a/Z18XE084.jpg
What is really a pain is that the cambelt idler sits on top of the mount which is great - cambelt back off again swap over the mounts :grr:
Also checked the tension on the belt again - the tensioner is in almost the exact same place from the old engine....
http://i2.photobucket.com/albums/y15...a/Z18XE085.jpg
And the new one......
http://i2.photobucket.com/albums/y15...a/Z18XE082.jpg
More stripping and swapping tomorrow after the Japanese Grand Prix .
Joff
Busy day today not too many pictures ...
Got on with swapping the engine mount around - cambelt off mount off, new mount on, cambelt back on and engine timed up again!
Once that was sorted next job was to change the sump for the meriva one with the sensor in - so I had to turn the engine upside down, no mean feat with the head on - just used the crane to lower it down ....
http://i2.photobucket.com/albums/y15...a/Z18XE087.jpg
Had to unseal the old sump , clean off the sealant, clean the new sump up and resealed. Once swapped over used the crane to lift it back up again.
Then got the the exhaust manifold properly bolted on along with the new thermostat ......
http://i2.photobucket.com/albums/y15...a/Z18XE089.jpg
Also swapped the starter motor over, then the big pipes that go from the back of the water pump along the piccolo tube and lastly the inlet manifold....
http://i2.photobucket.com/albums/y15...a/Z18XE088.jpg
I have taken out the injectors as I am having them cleaned at the local bosch fuel injection place, which is just round the corner from me which is handy !
More updates next week - my back needs a rest !
Joff
Some new CV's arrived today as the old ones were well past it ....
http://i2.photobucket.com/albums/y15...a/Z18XE092.jpg
Also picked up the injectors today, all nice and clean - the fuel injection chap said the filter baskets had a fair bit of muck in them - so I think a new fuel filter needs to be on the cards too.
http://i2.photobucket.com/albums/y15...a/Z18XE091.jpg
More updates over the weekend.
Joff