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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Wed May 06, 2020 12:09 am 
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Hello everyone. Hope you are all staying safe. Happy Cinco deMayo ! :SOMBRERO:

Got the rods and wrist pins back from the new machinist and they are excellent.

Time to bring everyone up to date. I haven't posted anything because it's all too embarrassing. :oops: Took a week off to finish the engine but that didn't work out for two reasons: Corona Virus. Wrong oil. :banghead:

Everything was going good until I started to verify the oil jets were actually hitting the holes in the pistons. Since I'd have to operate the lubrication system I used my transfer pump to push oil through the galleys with the block upside down. Unfortunately I chose the wrong jug of oil and pumped the oil with the carbon back into the engine. :banghead:

To remedy this, I started cleaning the engine with a solution of water, simple green, OxyClean and Marvel Mystery Oil. This did work but when I put new oil in the system there was very little oil pressure. So I decided to take it all apart again and start over. Stripped everything out of the block: Crank assembly, liners, freeze plugs, screw plugs, oil pressure relief valve.

Got a metal trash can filled it with water, Simple Green and OxyClean. Heated the solution for 3 hours until it started to boil then boiled the block for 2 hours more. Took it out and pressure washed it inside and out, and even in the oil galley and cooling jacket.
Image
The block fits nicely into a 30-gallon metal trash can.

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Having problems with my smartphone emailing pictures so I messed with the pictures to make the file smaller. No luck. Turned out I just had to turn the phone off and back on. That fixed it. Sorry about the crappy images.

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The water was yellow from the paint.

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Still wasn't sparkling clean, so I decided to Electrolyze it.

Already have a large plastic trash can so I fitted two construction stakes on either side for sacrificial anodes. Filled with water, Simple Green and OxyClean and started a 24-hour electrolyzing process. Next day the water was black and had a rusty grunge floating on the surface.
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Highlighted the battery charger clamp connections in MS Paint. It's important to connect the positive (+) lead to the sacrificial anodes and the negative (-) lead to the engine block. Electricity travels from - to + and the rust goes the other direction and collects on the positive anode(s).

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The inspector was asleep on the job.

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Power washed the block and most of the paint came off, and most of the carbon came off the cooling jacket around the pistons, and the calcium build-up on the rest of it.

I think I'll electrolyze it for another 24 hours to see if the rest of everything comes off.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


Last edited by CaptainDean on Wed May 06, 2020 11:04 pm, edited 3 times in total.

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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Wed May 06, 2020 9:10 am 
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Joined: Sat Oct 13, 2018 10:09 pm
Posts: 266
Location: Australia
The cat looks dead! sure you didnt find it in the water jacket!
You are very brave doing that sort of clean.
Are all machined surfaces protected?
Best not try it on head. dissimilar metals tend to setup their own galvanic call & inserts become loose. Aluminum soon disappears with caustic solutions.

Hope you didnt get CV19.
Stay Safe!

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Australian KJ CRD 2006


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Wed May 06, 2020 9:15 am 
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Posts: 147
Location: Central Iowa, USA
I was a little sad to see the yellow paint coming off of the engine. Dead cat - seen enough of those- not sad at all.

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2005 KJ CRD ~145K
V6 Airbox, Samco Hoses, Provent
Weeks 1&2, Thrush Glasspack
Facet Fuel Pump, Secondary Fuel Filter
GDE Eco Tune Full Torque
OME 1.5", JBA A-Arms and Top Plates
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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Wed May 06, 2020 12:02 pm 
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Never ever Hot tank an aluminum head or any aluminum part in any kind of caustic solution, it will eat up the aluminum.
First rule we learned years ago in an automotive machine shop.

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05 Jeep Liberty CRD Limited :JEEPIN:
Ironman Springs/Bilstein/shocks
Yeti StgIV Hot Tune
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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Wed May 06, 2020 11:38 pm 
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layback40: You cracked me up, "...did you find the cat in the cooling jacket..." I laughed out loud.

WWDiesel, layback40: Thanks for the warning about aluminum in the hot, caustic solution. Machine shops use highly caustic solutions in their tanks, but all I have are Simple Green (light acid) and OxyClean (Sodium Percarbonate and Sodium Carbonate. These substances form oxygen and hydrogen peroxide when mixed with water). Both seem gentle but I don't think I'll attempt electrolyzing the aluminum parts. Thanks for the warnings.

My wife was envisioning the block disintegrating into a pile of sand as though Marvin the Martian shot it with his Disintegrating Ray Gun.
Image

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Thu May 07, 2020 9:24 am 
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Joined: Sat Oct 13, 2018 10:09 pm
Posts: 266
Location: Australia
Its good to see you still have a sense of humor!
The drama you have gone through would have had many slashing their wrists!
Some that I have encountered have me thinking that a prerequisite for owning & working on one of these little CRD's is to have had your funny bone removed! But then I read a post from you & my faith in human nature is restored.
I hope your cat is fit & well & CV19 is not in your environment.
Here in Australia by shutting the borders the country has avoided much of the destruction. Being an island, I thought you may have been safe.

Most engine re-builders have a separate tank for any parts that have any aluminum in them.
Its a pity that in attempts to save the planet many good solvents have been banned. Chlorinated solvents used to be good for engine work.

I hope your wrist pin bushes solve a lot of the clanking.
Its spring for you guys so lots of progress can be made. Over here we are headed for winter, every time I think of working on mine a cold change happens.
Stay Safe
LB

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Australian KJ CRD 2006


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 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Thu May 07, 2020 3:15 pm 
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Thanks layback40,

I'm glad my jolly spirit refreshes you. Sometimes I think I'm simply insane.

Yes, Hawaii island has been closed. We had 75 positive CV-19 and 70 have been released from hospital, and no deaths.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


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 Profile  
 
 Post subject: Re: Hard to find noise -- clinking and clanking
PostPosted: Wed May 13, 2020 11:28 pm 
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Joined: Thu Oct 05, 2017 2:22 am
Posts: 394
Got the block painted yellow again and put the crankshaft back in. From here on out I will be frightfully careful of the oil I put in it. Polished the crankshaft journals, cleaned the crankshaft supports and put new bearings in all 5 crankshaft locations.

Dean.

_________________
2005 Jeep Liberty 2.8L CRD 248
Kona, Hawaii (Big Island) USA

Changed Turbo.
100,000-mile service.
Replaced harmonic balancer.
Noise in front axle or 3rd member - removed loose chain in transfer case.
Rebuilt engine - replaced #3 cylinder, piston, valves, head repair. Removed EGR.
Sheared bolts on TC. Replaced flex plate, TC, bolts.


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