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post #1 of 7 (permalink) Old 20-03-2017, 13:01 Thread Starter
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Well i made a balls up

Hey all

For anyone deciding to rebuild an engine or build a higher power variant of the k series (or any engine for that matter) for your ZS, dont do what i did! seems common sense to me now, but DO NOT MIX UP THE ROD END CAPS! i now have most of the engine together only to now discover that the starter motor cannot spin the engine over

As it turns out, each end cap is just a little bit different between rods, and did i number them? did i ********! so now i have to remove the head again (brand new 60 of head gasket ruined) in order to remove the oil rail and re-do all the bottom end caps!

Not a happy bunny

cheers all

Roo
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post #2 of 7 (permalink) Old 20-03-2017, 13:25
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Opps thats not good
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post #3 of 7 (permalink) Old 20-03-2017, 23:00
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Unhappy

Bad luck mate, sorry to hear that
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post #4 of 7 (permalink) Old 20-03-2017, 23:03 Thread Starter
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Well after storming out to the garage i have removed the head and oil rail, swapped the end caps on cylinder 1 and 4 around and you can now turn the engine over with a half inch ratchet as apposed to having to use a breaker bar which is a bonus i suppose, so tomorrow i am off exploring to try and find a torque wrench to re-do all the conrod bolts and head bolts AGAIN

on the plus side at least nothing exploded
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post #5 of 7 (permalink) Old 20-03-2017, 23:28
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If headgasket hasn't undergone a heat cycle it is re-usable so long as it is undamaged.
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post #6 of 7 (permalink) Old 21-03-2017, 10:52 Thread Starter
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i bought a new one anyway, as we needed to rotate the crank with the head off we ratchet strapped a piece of wood over the gasket to hold thew liners in place so it will be damaged now

thanks for that info though, it will most likely come in useful when i remove the head again to correct another mistake i have not yet discovered lol
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post #7 of 7 (permalink) Old 21-03-2017, 11:13
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Bad luck happens to us all at some point, I put a new clutch in my 45 only to realise I hadn't put the thrust bearing in 🤔
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