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Well its a dark day in 3.4 world for me today. I got my DME unit back from Steve yesterday. (still no splitter from Andial) I hooked up one ignition circuit so I could at least start the car and move it in and out of the shop. When I fired it up it sounded like I had something rattling around in the combustion chambers. (like rocks in a blender) Not a good sound to hear on a fresh engine! I freaked! I waited till my other co-workers got to the shop to see what their take on it was. The noise was the loudest on the left bank of the engine. My first thought was that the pistons were kissing the heads. They thought that there might be something that dropped into the intake on that side.
Either way...not good news. I pulled the engine back out of the car today and tore it down till I found out what was wrong. I screwed up big time!!! I miscalculated my deck height. I have a new top end gasket set with custom barrel base shims coming from Wrightwood Racing as we speak. Maybe I will be back to where I left off by Saturday. Lucky for me there was no real damage to speak of.
In the first picture you can see a dark line about an eighth of an inch from the edge of the piston. Thats the piston saying "hello" to the cylinder head. Very clear in the third and fourth pictures.

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Old 03-29-2006, 04:52 PM
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It it possible that the heads only need to be chamfered to make up for the fact that the bore is larger now by 3mm?

Michel

Last edited by Michel J; 03-29-2006 at 07:32 PM..
Old 03-29-2006, 07:28 PM
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Quote:
Originally posted by Michel J
It it possible that the heads only need to be chamfered to make up for the fact that the bore is larger now by 3mm?

Michel
I don't know if that would work. There isn't much room to chamfer because the intake valve comes pretty close to the edge of the combustion chamber.
-Chris
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Old 03-29-2006, 07:38 PM
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That sucks synroid. I've had the experience of hearing "bang, bang, bang" when starting up a newly rebuilt motor so I know how you feel.
What was your deck height? (Measured at the very edge of the piston.)
-Chris
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Old 03-29-2006, 07:44 PM
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OK I know this one and Michel is right the combustion chamber is still at its original diameter yet the cyl is now 2mm larger. The heads have to be chamfered to compensate. This will allow the piston to come up and will stop any detonation problems due to the sharp edge of the head protruding into the chamber.

Maybe a deck height check would have shown this before assembly?

Cheers

Mark......
Old 03-29-2006, 08:10 PM
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with the JE's I didn't have an issue - with the Mahles We had to chamfer, add .25mm to the deck height AND cut .5mm reliefs in the valve pockets. What cam?
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Old 03-30-2006, 07:54 AM
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The heads were chamfered. It was just a simple mistake on my part. I only had .021" of an inch deck height. I need .040" - .045". I won't be making that mistake again.
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Old 03-30-2006, 08:01 AM
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Syncroid,

Keep us informed on the progress. At present, I am building a 3.2 CIS motor and am considering going to a 3.4 like yours.
see link below
CIS with a 3.2 or 3.4. Is it worth it?

Cheers,

Michel
Old 03-30-2006, 04:26 PM
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Quote:
JeremyD
What cams?
Stock 3.2 cams. Nothing special.
Quote:
Michel J
Keep us informed on the progress.
I will do that for sure. I have my camera at work and will try to take pics this time around. When I assembled it last time I was too focused on all the little mods like plug wire arrangement, heater back date fabrication pieces, etc......etc. I will try and remember to post pics of all of those little pieces.
Sounds like the only difference in the motor you want to build is that yours is CIS and mine is Motronic. Would be interesting to drive them side by side for comparison of feel.
Michael I read your thread for your motor. I hope you enjoy your potential project as much as I have been enjoying mine. Even with the set backs that I have had...its been fun for me and a learning experience.
When I go back and read this thread that I started "Pistons Euro vs. USA" I crack up at how un-sure I was on what I really wanted to do. If the wifey only knew what it really cost.... I'd be in big trouble! Gotta love that black budget program!
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Old 03-30-2006, 06:49 PM
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You are not kidding about black budget!! If the wife only knew...I am always on the lookout for great deals, but, putting an engine project like this together requires some serious cash(for me at least) and there are not many ways to go on the cheap. It's all fun though :-)
Old 03-30-2006, 08:33 PM
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Euro piston/cylinder are fine

I just got done rebuilding my 3.2 and the euro piston/cylinders without twin spark are fine.

Prior with stock Mahle, i had pingining every now and then. Now its literally a whole new motor with alot more steady kick all the way through the poewr band with no pinging.

I have 800 miles on the engine and it feels better than it ever has. Other upgrades were only Sport and Pre-muffler and SW chip.

Go with the Euro pistons......
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Old 04-05-2006, 08:19 PM
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Its going back together today! Yippie!

More pics to follow.
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Old 04-07-2006, 08:25 AM
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More progress.
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Old 04-07-2006, 11:12 AM
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Getting closer.

This is the heat sheild I made to keep my plug wires from roasting.
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Old 04-07-2006, 12:53 PM
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Old 04-07-2006, 02:12 PM
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She lives! I got the engine stuffed back in and fired it up on one ignition circuit. Sounds great! No more rocks in the blender sounds. Now I can't wait till the splitter is available from Andial. At least now I can drive the car in and out of the shop and not have to push it.
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Old 04-07-2006, 04:29 PM
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Well I got my splitter today from Andial and installed it.

I got to drive her for the first time in two months. The bottom end pull and the smoothness is incredible! The motor is not broken in by any means but I can already tell a huge difference. Every motor I build always sees redline on the first road test. (only after making all the adjustments necessary...CO%, timing, etc...) She purred all the way to it and seemed to want more. Tomorrow I plan on taking her for a nice road trip over to Santa Cruz through the hills. I have to laugh! First thing the wife did when I got home is take the keys and says "I need to drive this...NOW!" She approved!
I questioned myself on doing this whole upgrade project whether or not it would be worth it. I am not disappointed!
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Old 04-14-2006, 09:02 PM
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