QUick rebuild, interesting finds. Completed 12/13/10

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quicksilvr
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QUick rebuild, interesting finds. Completed 12/13/10

Post by quicksilvr » Fri Dec 03, 2010 11:30 pm

Here's a bunch of pictures of what's been happening in my garage recently. Nothing special really, but I wanted to post some of the wear item's for posterity sake.

2000 SOHC, 3 speed auto. Been 100% stock it's whole life, which is 162K miles. Our family purchased it with 65K miles on it (i think?). During it's 100K miles with us, it had regular oil changes with Phillips Trop-Arctic synthetic blend. More recently it was getting Valvoline full synthetic, but probably only the last 10K miles. Plugs, wires and filters all changed as needed. The one thing we put off was the timing belt and water pump. It was never done.


Here is what we found during our complete tear down process:

The car
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Starting in...
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Water pump looked good itself. Suprisingly good. Wasn't noisy, spins smoothly, no obvious cavitation wear....
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The block showed some slight corrosion damage around the water pump mating surface....not much, but more than I expected. You can't see it in the pics, too small.
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The timing belt looked good at first gander, but then we saw this:
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Remember, this is 160k+......so really not too shabby for OEM quality.



Pulled the head, main goal was to replace all valve seals. Other goals soon followed...
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This is what the exhaust valves looked like. There is a mostly cleaned up one for comparison...
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The valves and the valve seats on the intake side were fine, just a quick clean on the valves themselves and they were good to go. However, the valve seats on the exhaust side were awful. We cleaned the valves completely, and then lapped all the valves in. The combustion chambers are still pretty dirty, but all the big carbon buildup we cleaned off.

Before:
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After:
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The original valve seals were extremely hard....the rubber felt like metal. It had a little give left, but was very brittle. None of the original seals were visibly broken or damaged.

We also discovered that camshafts don't last forever. It looked good at first glance, but they we saw the exhaust lobe on cyl 1. Ouch! The roller on that lifter looks fine though.

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The rest of the cam looked fine
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Dropped the oil pan, and pulled the pistons to replace rod bearings and rings. The bearings looked good, cylinders looked good (still noticeable cross-hatch), but the pistons were pretty dirty, especially the oil ring. And lots of buildup on the domes. We also found one broken 2nd ring....we deduced that it must have been broken during engine assembly at the factory, and because it was just the second ring, nothing got done about it.

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Pics of pistons coming, as well as anything I see worth snapping a shot of while we finish up and put it back together.
Last edited by quicksilvr on Mon Dec 13, 2010 10:47 pm, edited 1 time in total.
-Dave
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2001 Dodge Neon R/T

quicksilvr
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Post by quicksilvr » Fri Dec 03, 2010 11:35 pm

Oh yes, and the exhaust manifold was cracked in two places. We had a couple spares laying around, one with only 20K miles on it, so that was an easy fix.

Enlarge the picture, and look in the very middle of the manifold. You can barely see (in the pic) a white line or white spot. That's the top of a 3 inch long crack. I didn't take any pics before we threw it away, sorry. The other crack was much smaller, on the #1 cyl runner. The big crack in the middle was the one that would have started making lots of noise pretty soon...

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The new one:
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-Dave
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2001 Dodge Neon R/T

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MyNeonSaysHi
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Post by MyNeonSaysHi » Fri Dec 03, 2010 11:37 pm

Great documentation. Looks like fun

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Post by neonpla » Sat Dec 04, 2010 11:54 pm

I need to do this on my dad's 01 soon... its on its last leg.

please put as much detail as possible, looks great already!
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Post by Fuzzyneon » Sun Dec 05, 2010 12:30 am

my exhuast mani was cracked to but one spot


awesome log love the detail very informational
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Post by TNK » Sun Dec 05, 2010 2:33 am

you lied. it's not 100% stock. it has clear corners. and that's assuming the 'Stones are factory...



:lol:
great log, very cool to read through.
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quicksilvr
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Post by quicksilvr » Sun Dec 05, 2010 2:17 pm

TNK wrote:you lied. it's not 100% stock. it has clear corners. and that's assuming the 'Stones are factory...



:lol:
great log, very cool to read through.

:beatstick:

:lol: Stock mechanically. It has R/T springs and struts, 'stones, clear corners, tinted windows, and a trailer hitch. Woo hoo!!1!!!!!11!!!!
-Dave
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2001 Dodge Neon R/T

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Post by Marcel » Sun Dec 05, 2010 2:48 pm

very interesting! :)
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quicksilvr
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Post by quicksilvr » Mon Dec 13, 2010 8:41 pm

Here's the rest of the work. Finished up the the car today (finally...only have a couple hours a week to work on it), and it runs nice and purdy.




Pistons after cleaning. We used an old piston ring with a sharpened end to clean all the ring grooves. And a tiny drill bit to clean the oil drain back holes.
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Block prepped
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And the cylinders honed...I used a new Flex Hone brand "dingle-berry" style hone.
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The next picture I took, it looked like this>
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The putting together process goes pretty quickly. It now has a '95 SOHC cam in it, so I'm sure it's making crazy power. ;)

Finally, it can leave the garage once and for all! Hopefully its good for a big chunk of mileage before anything major needs work again. For everyone with a high mileage Neon, don't press your luck with much more than 150K on the original timing belt. And keep on eye on your oil consumption...if it gets bad, your head will look like this one did. Viva la Neon!
-Dave
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2001 Dodge Neon R/T

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