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I hope everyone is enjoying reading about my 99 ramblings... If you don't want to read everything, the last five sentences are where its at...
If you've read any of my recent posts you'll see that I've rebuilt the engine in my '80 GLi and just installed it.
A little background: This engine was built up by a friend of mine but seems to be bad luck. He built it up with some advice and help from some other SAAB people. The pistons are 1/2mm overbore, flat top, very light weight, thin-walled aluminum pistons. The bores for the wrist pins are oversized for a SAAB so they had a bronze bushing pressed in and then were straight line bored, off center (non concentric), to fit the SAAB wrist pin and make the piston rise up above the deck ever so slightly (maybe 0.010"). The engine was balanced. The head is milled down to its minimum spec and the cam is an MSS race cam (first level race cam) with the proper lifter buckets, compensating shims, and dual valve springs. There is also an adjustable timing gear and lightened flywheel.
When the engine was first assembled it was driven a short distance before the waterpump bearing froze. This stopped the waterpump and the auxiliary shaft. The auxiliary shaft gear broke and the pistons hit the valves. The engine was pulled, the broken gear was replaced (along with all the timing gear - chain, tensioner, guides), the waterpump was rebuilt, and a stock head was put on. The car was then run maybe 100 or 200 miles before hitting a patch of ice at high RPM. The engine was over-revved which caused the cam carrier to shatter. The car was driven a few miles to try to limp it along but then had to be towed.
I got the engine in part of a package deal and should have known not to use it... I had the valves in the original head replaced and I cleaned the inside of the lower end up a little and installed it in my '80 GLi. I heard some loud clatter that sounded like the valves were out of adjustment. I checked them and they weren't. Figuring that the engine had some rod bearing damage from ingesting cam carrier bits I pulled it out and tore it down. While it was apart I noticed that the timing chain had been hitting the valve cover. I had the block cleaned and I cleaned all the other parts myself. I installed new bearings and a new timing chain, replacement crankshaft and auxiliary shaft chain gears (the originals looked a little worn) and inspected all the other parts. When I installed the timing gear I made sure the chain was good and tight and everything was lined up as the manual states. Now that I have the engine running again, I still have the same clatter noise. It makes noise while idling and while increasing the rpms, but if I let go of the throttle the noise goes away until the engine returns to idle. I've listened with a stethoscope but its really hard to pinpoint the noise.
Does this noise sound like anything familiar to anyone?
posted by 68.112.254...
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