Technical 594-A1 000 engine rebuild.

[BucsaBogdan]

I have seen them on Axel Gerstl as well. They say it’s original Fiat part.

 

[the hobbler]

Found some on the Axel Gerstl site

If your machine shop can't bore-out the cam-follower holes, you will probably have to ream them out---very carefully!

 

[BucsaBogdan]

Thanks “Toshi 975” and “the hobbler” for the help you are giving me.

In this moment my options are:

a.)-try to find a new machine shop who can do the work and get oversize tappets
b.)-buy new standard tappets and hope that the amount of ware in the crankcase is small, and with the tolerance ( 0.007mm to 0.042) between the block and tappets I will be in spec.

If the tappets would be cheap option b would be worth a try, but since they are 30 euro a piece it’s an expensive trial))
Thanks again for your help

​

 

[BucsaBogdan]

Hello,
As per the hobbit’s advice I put self tapping inserts in the exhaust flange mounting holes.
I used a 10,5 drill bit and I’m quite happy with the result.
Thanks again “the hobbit”

 

[the hobbler]

Hello,
As per the hobbit’s advice I put self tapping inserts in the exhaust flange mounting holes.
I used a 10,5 drill bit and I’m quite happy with the result.
Thanks again “the hobbit”

Well done Bogdan---you've done a good job. 2 little tips---(1) don't forget to secure the manifold to the head with two PLAIN nuts on the the stud (which I assume that you are going to cut down in length)--1 to secure the exhaust elbow and the 2nd to 'lock'the 1st nut and (2), you will find it easier if you put the bolts which will secure the exhaust to the 'elbow' in place before you you fit the 'elbow' to the cylinder head---it means that you can use slightly longer bolts to secure the exhaust to the 'elbow'. You don'thave to bolt them up--just put them in place.

 

[BucsaBogdan]

Yes, i cut them down. This is the finished job. As per the 2nd tip, I did not have the bolts with me. But I’m at the stage where I’m doing a mock up.

Sadly the project took a blown a couple of days ago when I was checking the tolerances on the engine.
The cilinder-piston clearence is 0.10mm and 0,14mm on the second cylinder.
The repair manual states it should be 0,07-0,09mm.
Now i’m on the hunt for 594cc cylinders that have not been honned out. My pistons are +0,40 oversize
I will sadly have to search for a new machine shop for the future.

 

[BucsaBogdan]

Finaly some assembly!

Hello,
It’s been a long time since I’ve posted and happy to say that I have some important updates.

I got all the parts from the machine shop and all the parts needed to start assembly.

Since it’s my first ever engine build I really did not know what to expect.

I want to post the problems I encountered so maybe someone will not make the same mistakes i did.

1). The back main bearing that holds the crankshaft (at the distribuitor) was a bit bigger than the old one.
It was a bit of a small surprise cause I was woried that the big end play will be to large. But to have none so ever was a shock)
When I tightened the 32mm hollow bolt at the oil filter, the crankshaft got stuck.
I decided to sand down the aluminiun part of the bearing until I have enough clearance.
I took my time and ended up at a 0,25mm play. (Found a post on the forum and decided to go with it) (thanks The Hobbit)

2) the copper sealing ring/gasket between the block and cylinders was to small and would not fit on the cylinder.
I chose to use the bench grinder to somehow grind a small part of the gasket.

I attached a couple of pictures.
I still need 2 days to fit the rest of the parts and try to start the engine. The parts are there, but I have no time

Thank for all your help.
Six months of work) the last picture is how I bought the engine.