Engine GA000099, An early GA engine rebuild thread Options

[Superhawk996]

Last week I bought engine GA000099 from Freezing914 in the hopes of picking up some spare parts to support rebuild of the engine that came with my vehicle.

During the teardown of my vehicles engine, it is quickly becoming clear that the engine was abused by some DAPO. Cooling flaps and thermostat had been removed. Rust in the sump. The crank was scored and already 0.010" undersized. The oil pump was torn up. This is just the tip of the iceberg on the engine that came with my vehicle. (IMG:style_emoticons/default/chair.gif)

14 hours of driving seems to have netted me an engine that might be worthy of a rebuild. (IMG:style_emoticons/default/piratenanner.gif)

This engine appears to be bone stock. D-jet mostly complete. As an added bonus I discovered upon teardown that none of the cooling tin fasteners have ever been disturbed. No screwdriver marks!

But . . . like any engine of this age and unknown origin, it absolutely needs to be gone though.

[Superhawk996]

I did notice some differences in this early 099 casting vs. the later version that came out of my car.



Note the differences in casting lot number/date codes

There also appears to be an error in machining the flywheel end main bearing bore.



It looks to me like whatever tool they were using to face mill the case stopped short of a 360 degree revolution.

I can't quite visualize what tooling they were using to cut this surface. The sharp edge, straight line and angular surface left aren't what I'd expect from fly cutting, or a face mill.

Curious if anyone has seen something like this before?

[Superhawk996]

There also appears to be an error in machining the flywheel end main bearing bore.

Note the step mismatch between case halves (yes, the case half ID stamps match so this wasn't 1/2 of one case and 1/2 of another).

There was also that little unmachined tab that partly obscures the main seal oil drain back hole.

I finally got around to setting this GA000099 case up on the mill to fix the mismatch in the Rear Main Seal counter bore area.

Setup and dialed in the bearing bore.



Finished product.



If anyone is interested, I can post a few more details and a short video but mostly wanted to get this fix documented.

Next up: Need to pull all the oil galley plugs in order to get full access for galley cleaning.