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]

So I spent some time to make sure my mill was set up perfectly. When fly cutting surfaces, if the head of the mill isn't perfectly square to the table, you will end up with an imperfect surface finish that will be prone to leaking.

For any of the guys doing machine work, I love this EDGE Technology head tram. Makes the work pretty quick and easy . . . relatively speaking vs. old school singe dial indicator.



Dual dial indicators make the job so much easier.

The only problem was that I chickened out on cutting GA000099 1st. I decided that I had better make sure I liked the result before committing to cut 099.

Instead I cut GA004310 that I viewed as a little more disposable.

As it turns out, everything worked out OK.

Here is a partial cut at about 0.004". You can see the surface cleaning up but still haven't got into all the old material.



Ultimately, I had to cut a bit more than I was hoping. This case showed about the same 0.004" from flat as I showed earlier on the GA000099 case. However, it took 0.010" to clean it up fully which isn't a big deal since shims are easily available in 0.010" increments.

Here's the final clean up.



Happy with the result. Next time I'll cut GA000099!