Motor Maintenance



Motor Maintenance

No four wheeling for me this weekend.  I noticed my motor was leaking oil pretty badly last weekend so it was time to see what was wrong. 

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It took about two hours to get everything unhooked and the motor out.  While I am in there I am going to pull the A/C out and re-wire all the relays.  The rewiring plan involves making a plate that mounts under the glove box.  On the plate I will have a fuse, a power distribution block and the relays for the rock lights, ARB, headlights and starter.  I figure this should eliminate over 20 wires under the hood since only one wire from each relay will have to pass thru the firewall. Anyway, that's tomorrows project.

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One other problem I have had since I rebuilt the motor is it would leak a lot of water down the side under the intake manifold.  It looks like the head gasket is the culprit.  While I have the motor out I am just going to replace all the gaskets.  I am hoping the head is not warped, the water leak only seemed to occur when cold.  If I didn't top off the radiator it would eventually stop leaking which but the water level would be a couple inches low in the radiator.

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Here's a before shot of the wiring, we'll see what I can do to clean it up.

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As you can see the timing belt is soaked in oil, not good.

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After 5000 miles everything looks pretty good.   The does seem to be a lot of build up in the water jackets but I did run a couple bottles of block seal thru the system trying to stop the water leaks.

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I had cleaned up the oil pan from the parts truck a while ago so I planned on using that oil pan to save me some time.  When I tried to mount it to the block it wasn't fitting.  Seems they changed the design of the oil pickup somewhere between 86 and 88.  

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By 6pm I had nearly everything back together.  On Sunday I'll install the new timing belt, new plugs, the distributor and alternator.  I may also build a new power steering bracket to move my pump down lower since the A/C compressor is no longer in the system.

Update 4-12-02

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Here's a picture of my relay panel I mounted behind the glove box.  This eliminated about 20 long wires from under the hood.  

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After replacing all the seals the motor was still leaking, this time oil from the back of the motor, looked like the head gasket.   My suspicions were confirmed when I saw a drop of oil seep out and roll down the side of the block.  I did a little investigating and found out the Rock and Safety brands of head gasket are incredibly cheap compared to the stock or Felpro gaskets ($16 vs. $48).  So I picked up a Felpro and noticed a couple differences right off the bat.  First thing I noticed was the holes for the two large oil passages on the back of the block had a metal ring around them on the Felpro head gasket.  The other two I had tried did not have this.  Also the material was different, Felpro was a light gray vs. black. The Felpro also seemed to have more metal showing on the bottom but I can't confirm that.  Needles to say it looked like better gasket to me.   So far it is leak free after the first test drive (the last two leaked immediately on startup).

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In preparation for Moab I built some brackets to get my side mirrors back on the Zuk (needed to be street legal in AZ).   The brackets bolt to where the stock hinges did.  I also picked up an aluminum 15x8 rim for my spare (aluminum to save weight).  I ended up mounting it on the stock carrier but when I tube the back end I would like to get it down low and centered like in the second picture.