Cylinder Liner broken pieces in oil pan

[martinv]

The cylinder liner at the front of the engine broke up and also took out the piston oil jet tube thing.
Has anyone here done this repair and how did it go?


Part 1: The noise it makes (I believe this is after most or all of the liner broke up):

M35A2 Cylinder Liner Repair - Sound (part 1)

This was the first sign something was wrong. Seconds after the video, the noise got much worse.

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See the entire series here:

M35A2 (Deuce and a Half)

Browse the most recent videos from channel "M35A2 (Deuce and a Half)" uploaded to Rumble.com

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UPDATE 7-16-2021: It is running again and has survived a few trips.

 

[Menaces Nemesis]

Very sorry to hear that... From what I remember, seems most agree that it's better to just replace the engine, as little bits may have been pumped through the oil and can find their way into other components, as well as the unknown mechanical stresses that other components may have been exposed to during the failure.

 

[cattlerepairman]

I've rebuilt a multifuel. I am not claiming to be an authority on the matter.
You can get a piston and liner and do it in frame, pulling head and oil pan.
Before buying any parts I'd open the engine up and see what's what. There is a risk of metal having gone elsewhere and clearly you'd take a good look at the mains with the pan off and any other carnage you can find. I'd probably check the turbo and blow the oil lines out with shop air.
The oil pickup has a screen and the oil filters do their part...may be worth rolling the dice if everything else looks ok.

At the bare minimum, piston and liner can be had for $150 a hole. Oil squirter maybe $50, dunno. Headgasket is about $90, other gaskets and assorted stuff..maybe another $200. That's assuming nothing else needs fixing and you don't decide to do more just because you have it open

How much can you get a good running takeout engine for? What's your time worth? How lucky do you feel?

P.S check the classifieds for a long block that was running, for less than a piston and liner cost...

Sent from my SM-G950W using Tapatalk

 

[gimpyrobb]

If you want, see what you need and post up. I have a parts motor I could pull and ship if you'd like.

 

[M37M35]

The first step is to disassemble as far as necessary to find out what all is damaged. Then depending on the damage, decide how involved you want to get with repairs.
I had a damaged piston and liner in mine. I just replaced them with a used take-out piston and liner from a member here. That was maybe 1,000 miles ago, and so far so good.

 

[cattlerepairman]

@martinv Have you decided on a plan?

 

[martinv]

Thanks for the replies and good info. Disassembly is in progress. My plan is to do some inspection and figure out if any more damage exists. So far i'm leaning toward repairing it. I ran a tiny camera into the injector port and could see some chunks on top of the piston also as expected. I will pull the head off and inspect closer. Short video clip compilation here:

M35A2 Cylinder Liner Repair - Inspection and begin tear-down (part 2)

Investigating M35A2 and beginning disassembly around the engine. Oil pan removed. Inspection of broken parts in oil pan. Inspection underneath engine.

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[cattlerepairman]

Good video! What was the noise like? Like a tug boat? chug chug chug?

 

[martinv]

Good video! What was the noise like? Like a tug boat? chug chug chug?

Fairly consistent, but louder than normal, followed by inconsistent banging, clanging. The noise seems to agree with the liner issue for 1 piston. My guess is the liner was damaged partially at first but still mostly in place. After idling a couple minutes it slid down and broke up completely causing the sudden change in sound to a more inconsistent metal clanging sound as it broke up. After this sequence happened twice, I restarted the vehicle so I could move it to my driveway for repair and it seemed odd at the time that the sound was no longer the loud clanging although it was louder than a normal engine sound (shown in the video).

If I recall correctly the sequence was:
1. Startup, seemed OK,
2. After about 1-2 minutes, sudden clanging, banging started.
3. Quickly shut off vehicle.
4. Think for a few minutes. Contemplating if repairing the vehicle will be as enjoyable as driving it for the summer.
5. Start vehicle to see if noise is still present and noise at first was surprisingly closer to normal.
6. Louder noise came back.
7. Shut off vehicle.
8. Decide to risk driving the vehicle onto my driveway for inspection repair.
9. While driving the noise didn't seem as horrible. This may be because the entire liner had already completed its journey to the oil pan.

 

[martinv]

Part 3: Manifolds, head, piston and liner remains removed and inspection:

M35A2 Cylinder Liner Repair - Piston 1 removed and inspected (part 3)

Continuing disassembly, removal of piston 1 and inspection..

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So far the damaged parts are:

1. Piston
2. Cylinder liner
3. Oil jet thing
4. Gaskets

 

[pigpen60]

Part 3: Manifolds, head, piston and liner remains removed and inspection:

M35A2 Cylinder Liner Repair - Piston 1 removed and inspected (part 3)

Continuing disassembly, removal of piston 1 and inspection..

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So far the damaged parts are:

1. Piston
2. Cylinder liner
3. Oil jet thing
4. Gaskets

View attachment 830207

Thats a keeper!

 

[pigpen60]

Thats a keeper!

Meaning the piston.

 

[cattlerepairman]

Great making those videos. They will help someone jump off the cliff and tear into one of the LDT/LDS engines for the first time!

 

[SCSG-G4]

Several of us here on SS have piston assemblies (piston, liner and oiler) because we got them back in the early 20-teens when a lot of that stuff got surplussed. Finding where they have been squirreled away will be the problem.

 

[martinv]

Meaning the piston.

Yes, it is a great piece of art. One of a kind.

UPDATE 4-10-2021: I got a NOS cylinder liner kit that included a piston, piston pin, rings pre-installed, and even the piston cooling nozzle oil jet assembly.

Piston has what looks and feels like some sort of black coating:


Wanted: Cylinder head wrench.
This will allow torquing the head bolts that sit under the fuel injectors. . I think it is 7/8" for the head bolt side with a 3/8" or 1/2" drive so a torque wrench can be applied to the top. Another option is to weld some wrenches/parts together to make one.

 

[cattlerepairman]

O2 sensor socket has worked for some. You just need to do the torque math because of offset.

 

[M37M35]

I ended up just making my own from a cheap box wrench and socket.
Just have to keep the offset in mind when you torque them like Cattlerepairman said.

 

[gringeltaube]

I ended up just making my own from a cheap box wrench and socket.
Just have to keep the offset in mind when you torque them like Cattlerepairman said.

Cheap is good! And no torque correction needed is even better.... like this one.

 

[martinv]

My version of the cylinder head wrench is complete:

 

[martinv]

Update 4/24/2021:

Removing valves, inspecting valves, cylinder liner cleanup:

M35A2 Cylinder Liner Repair - Valve lap and liner cleanup (part 4)

Removing valves, inspecting valves, cylinder liner cleanup.

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Cylinder head wrench:

M35A2 Cyclinder Head Wrench Build

M35A2 Cyclinder Head Wrench Build. This tool allows reaching in the the recess under the fuel injectors for torquing the head bolts. The alignment of the drive and wrench head remove the requirement f

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