Rebuild Kit for 1.6 IDI

[dubCanuck1]

OK, looking more into this, I realize that the 1.6 TD may have to get rebuilt from the ground up (To do the rings, you have to pull the whole damn engine apart pretty much. If you've got scoring of the cylinder, you have to get it honed/bored out. The head might have to get planed, etc......).

I didn't post this in the Modest Performance mods thread because this is what I would consider the worst case scenario, but I need to know what it would cost to a) have the whole engine rebuilt by someone else, and b) what it would cost in parts and machining (if necessary) to do it myself (I obviously don't have a CNC machine or machine shop in the back yard).

Preferably in Canadian Dollars....

Thanks guys......

[jtanguay]

http://www.zsimports.com/Mechanical/index.htm

gives you an idea of some pricing for just getting a whole new motor

[935racer]

Rebuilds really come down to how good a of a job you like to do. Some people consider a rebuild just rings and bearings, this makes me cringe.

Here is what a rebuild out line looks like when we rebuild engines.

Block fully stripped ready to go to machine shop
This is what gets done everytime:
hot tank                        $40
resurface block              $85
R&R aux brngs               $12
Bore and hone               $85x4
Re bush conn rods         $15x4

New parts that now get reinstalled into the fresh engine block:
Oversized pistons (includes rings, wrist pins and clips)   $87x4
Main bearing set                                                         $45
Rod bearing set                                                          $20
Aux bearings                                                              $20
New main bolts                                                           $20
New rear main seal                                                     $10
New crank seal                                                           $10
Fiber oil pan gasket (not used if windage pan is)                                                                                $6                                  New windage pan with rubber gasket                            $45
New frost plugs                                                           $10

Thats what a bottom end rebuild looks like when we build one or ship it out.

I am at home right now and do not have the head rebuild prices with me but they vary greatly, sometime valves need to be replaced, sometimes they don't, valve guides usually get replaced along with lifters and valve springs. Valve seats should also be ground, and if old valves are used a 3 angle valve grind is done. I also replace the stock valve cover gasket with a rubber one wich also requires differnt VC studs. Due to the performance minded nature of our customers port matching and polishing is often done as well.

These prices are CAD, as you can see just a basic longblock rebuild hits $1500 pretty easily. These costs are obviously without labour. It isn't cheap but these rebuilds are very complete and high quality and are ready for years of use and abuse.

[dubCanuck1]

Thanks guys. Just the stuff I was looking for. The old man's car is going to get my old non-turbo engine while I do the rebuilding. I plan on doing it, as Dave says, "the right way".

[935racer]

You will never be dissapointed in doing it the right way. I've built a bunch of these IDI engines and they are all rock solid and ready for tuning. Like all things, do it once do it right.

[dubCanuck1]

Reviving this thread as it's now time to have it done. I'd send it down to you Dave, but shipping would probably add another couple hundred in both directions. I'm not paying for it, but I have a vested interest in saving some money on it (It's my father's car and I KNOW he's not a millionaire).

I'd prefer not to oversize the bore unless there's evidence of scoring already in the cylinders (to be evaluated by the machinist). In the event that one is needed, what does the machinist need to bore it to? The machinist I'm working with is someone who's done well for me in the past, so I can count on the quality of the work being done.

Here's the list that you gave earlier. Can you verify that I've split out the tasks properly?

Machinist
hot tank $40
resurface block $85
Bore and hone $85x4
Re bush conn rods $15x4 (Is this something I can do or do I need specialized equipment?)

New parts that now get reinstalled into the fresh engine block (To be done by me)
Oversized pistons (includes rings, wrist pins and clips) $87x4
Main bearing set $45
Rod bearing set $20
Aux bearings $20
New main bolts $20 (If these are the stretch bolts, I've already got them)
New rear main seal $10
New crank seal $10
New frost plugs $10

Parts already purchased for this:
Windage tray
Stretch bolts for head

Do you have all the parts needed for the rebuild? I'm assuming you do, since your shop does this. I can get the machining/hot-tanking, etc.. done in Calgary, but you've never steered me wrong in the past. I'll keep that loyalty unless you don't have the parts.

I'll likely have to do some similar work on the head as well. We'll get to that once the finance department clears some more funds.

[wyldman]

Get the block hot tanked and checked out first.Measure the bores,check the deck,and check the crank,int shaft,and rods.I would bet you most of it measures out as good.More than half the time all you need is to hone the cyls (do it yourself with a drill),new rings and rod bearings.This will save you big $$$.Spend a little extra on a 1.9L headgasket,and a 1.9L windage tray\pan gasket.You can also port and polish the head when it's rebuilt,as you'll have some budget $$$ left over.

[dubCanuck1]

Yeah. Already got the metal 1.9 HG and windage tray.