2.0L engine rebuild?

Which Manual did you have? The only one I have for Series 1 is an Autopress one, which does have some additional data, but I would be very surprised if there is anything in it that is not in the factory manual.

Are you aware of the manuals available on CD from the AULRO shop? A quick look shows the Series 1 CD contains a number of Service Bulletins as well as the workshop and parts manuals. I would think getting this would be an obvious first step in restoring a S1. Also, buying at the shop helps support this forum!

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Originally Posted by JDNSW

Which Manual did you have? The only one I have for Series 1 is an Autopress one, which does have some additional data, but I would be very surprised if there is anything in it that is not in the factory manual.

Are you aware of the manuals available on CD from the AULRO shop? A quick look shows the Series 1 CD contains a number of Service Bulletins as well as the workshop and parts manuals. I would think getting this would be an obvious first step in restoring a S1. Also, buying at the shop helps support this forum!

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I have the factory parts and workshop manuals on CD. The service bulletins I have don't cover engine rebuilds. Any additional info would be welcome.

The main and big ends are badly scored and are going to need a regrind. Probably abt 20 thou undersize.

There is 10 thou piston-bore clearance which the engine shop says is marginal re reuse vs bore and oversize pistons. What would you lads do?

Chris,
Dunno how deep your pockets are, but the price of a set of replacement pistons (std or oversize) might help you decide. Another factor, what sort of mileage are you planning to clock up on the rebuilt engine? If not a lot, you might get away with simply re-ringing the standard pistons and re-honing the bores. Cheers, Rob S

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Originally Posted by LR1953

Chris,
Dunno how deep your pockets are, but the price of a set of replacement pistons (std or oversize) might help you decide. Another factor, what sort of mileage are you planning to clock up on the rebuilt engine? If not a lot, you might get away with simply re-ringing the standard pistons and re-honing the bores. Cheers, Rob S

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It is looking like $4k with use existing pistons (regrind crank etc) vs $5.5k with rebore and new pistons added.

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Originally Posted by cjc_td5

It is looking like $4k with use existing pistons (regrind crank etc) vs $5.5k with rebore and new pistons added.

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thats about right any thing up to 10.ooo on a full rebuild

As said above depends on how much you are going to use it. That bore size could go a little higher with the hone .

Chris,
If the budget figures quoted above ($4.5K - $10K) don't frighten you, I'd recommend getting crankshaft, rods and pistons balanced as well. I hear these engines (and most from this era) weren't particularly finely balanced in manufacture. You'll notice the difference! Cheers, Rob S

Can anyone tell me if the early 2.0l main crank oil seal is the same as the later 1955-58) main seal? I can only find listings for the 1955-58 seal.

The 1595cc motor never had a seal but a scroll on the shaft & a trough bolted to the rear of the block with a drain back into the sump. My guess seeing as the early 2L was a bored out 1595 cc it would be the same . When I overhauled my 1595 cc I had the scroll machined off & the late 2L seal bolted straight on in place of the trough. The scroll should work OK providing the scroll is not worn , the trough is clean & the drain back to the sump is not blocked . A lot of cars used this system infact Hillmans had a scroll on the front of the crank shaft as well.