alpine003

Sweet. You got my appetite wet. Keep the updates coming.

Ahsai

It's going slower than I'd like and the OCD in me kept me cleaning the parts as I took them off

Imo000

You think wirewheeling off the rust will make a difference. Unless you replate it, in 2 months it will look like it did before.

alpine003

Damn, I think you may have caught KK'itis. LOL

Ahsai

I know and I'm gonna coat them with rust inhibitor. Even without that though, they will be in a much better shape than before. The ones on my '03 are never in this bad shape and I didn't even use rust inhibitor.

Lol. Actually there's a practical side to this. I just waan keep the dust down in my garage to prepare for the rebuild if it happens. All the parts I take off have tons of dust on them and I need to store them in my garage.

Ahsai

To learn something, I sent the oil to Blackstone for UOA, TBN, and particle count tests. I've attached the report here. The aluminum is a whopping 34. Iron is 10 (since most already attached themselves to the LN magnetic drain plug) and copper is 13. TBN is 6.3 so the oil itself is still good.

The particle count is ISO 18/17/15, which is quite high as far as I understand. I've also attached the photo of the actual oil here, which shows the glitter.

UOA 6-18-2015 anonymous.pdf

mikeborden

Man, if you went by their comments, nothing is really wrong with the engine!

Of course, Jake has said that in the past.

I think getting an analysis is a good thing, but I think you need to draw your on conclusions, especially if you have an idea of what metals go with what parts in the engine.

BTW, that oil looks horrible!

phil996cab99

What is that crema (white frothy stuff)?

Ahsai

The frothy stuff was because I shook the used oil jug before I took the photo. There's no antifreeze in the oil.

Yea, I don't pay too much attention to the commentary but to be fair to them, the magnetic drain plug had picked up almost all the ferrous bits from the oil so they didn't show up as much in the UOA/particle count. Without the mag drain plug, I'm sure IRON would have been skyrocketing and the conclusion written could have been very different.

The other thing to note is the particle count (18/17/15) is ~3 times as much as that of the oil on my healthy '03 (17/16/13) for all particle size ranges. One thing that surprised me was you would think with that much visible glitter in the oil, particle size >= 100 micron should show up in the report but no, it's zero. I wonder if the ">=100 micron" really has an upper bound on the size of the particle they can count (note human hair is about 50 micron in thickness).

Ahsai

Update:
- All ignitions coils are cracked
- All spark plugs are in good shape
- Leak tested all cylinders at two positions, TDC (compression) and 180 degree before that (BDC). All cylinders have 4-8% leakage except cyl #4 at ~50%.
- Borescoped all cylinders. All cylinders are scored. #4 is the worst with lots of pitting at the top 1" of the cylinder and also at mid stroke
- No questions all cylinders and pistons are destroyed
- Bank 1 scavenger pump destroyed by debris by ingesting and grinding some like I suspected from the grounded metal pieces found in the oil sump.
- Bank 2 scavenger pump is in good shape except with a few slight scratches.

Took the pumps apart and now know exactly how they are constructed and how they work.

Next stop is the IMSB flange. Stay tuned...

Bank 1 pump



Bank 2 pump

Ahsai

Pics of the spark plugs:



All the coils are cracked at almost the same places:

alpine003

So now that the engine is no good, what are the next steps?

Any pics of the scoring and engine block?

Ahsai

The snapshot feature on my wifi borescope (using ipad as display) somehow didn't work and I ran out of hands to snap a photo while manipulating the probe. I will try to ****** some next time if I have a helper. Otherwise, we'll have pics for sure once the heads are off.

We all knew the engine is bad from day 1 so no surprises there. The only thing that surprised me so far is the engine could still run in such a poor state. I want to see if I can identify the origin point of failure so I'll keep stripping it down. We may or may not be able to find it but hopefully most of us will learn something.

We already know bank 1 scavenger pump ingested sizable metal bits, most likely picked up by the timing chain to the bank 1 head. Why all cylinders are scored? Maybe the piston jet sprays are all clogged that led to piston overheat? But then the main bearings should have been seized also. Will definitely check all the teeth on all the sprockets but from what we saw in the oil pan, those look like bearings.

Next is to remove the IMSB flange and check the LN bearing's condition. Then remove the cam covers and check the cams and lifters.

Flat6 Innovations

Cylinders are scored from debris that was splashed into them, suspended in the waste oil from the rod bearings. Centrifugal force delivers this oil there in great quantities.

I would not reuse the IMSB, it has been subjected to oil with debris suspended in it, and it has to have seen damage from that.

I see lots of collateral damage, but I don't see the primary failure as of yet.

Ahsai

Appreciate your expert comments, Jake! I knew you would show up sooner or later

That makes a lot of sense. I think the IMSB is the least of the problem (definitely not to be reused). Seeing how much the bank 1 scavenger pump is damaged, I wonder what the conditions of the cams and crankshaft are...