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Alucard7002
08-30-2012, 11:00 AM
Hi folks, been on here a while lurking and reading up on some VERY useful info.

I'm no mechanic, nor have I had any training apart from what my father and two older brothers have taught me over the years.

If you're interested have a look here for some of my/my Dad's previous work.

First Car (yes it ended up in a tree!) (http://www.rover800.info/forum/viewtopic.php?t=2549)
Second Car - Still going strong and on LPG now! (http://www.rover800.info/forum/viewtopic.php?f=2&t=8386)

Took me 5 days to shell this old 800 when I was 16 (4 years ago now! Seems a lifetime away)
https://lh5.googleusercontent.com/-RgUqfDMElFg/SmCNVCsc07I/AAAAAAAAB5I/XI3MxFpaMzU/s640/IMG_3170.JPG

Firstly, many many HUGE thanks to Smaay, without his guide removing the engine would have been a little more difficult.

So here's the story,

Bought a 2001 Celica VVTi (GT is the equivalent US spec i think?)
1zzfe with the 6 speed 'box

Bought for not alot off ebay with 98k (ticked over 100k in my ownership)

Noticed she burned a little oil at first, then after a while it was so bad clouds of blue smoke and chunks of oil came spitting out the back when driving "enthusiastically"

I had already researched the problem of stuck oil control rings and decided to pull the engine and box this summer and re-hone and re ring it.

I'm on a tight budget so only replacing parts that need it. Not my first choice of method but the only one I can afford on a University Student budget.

TL:DR Here's some shiny photos of the beast and most of the work.

https://lh5.googleusercontent.com/-ahBNCeEpzTc/T4BTKT9rCCI/AAAAAAAAFRg/H93t23CJgnA/s640/SDC15718.JPG

First job was a new backbox a week after I bought it, just a little rusty under there!

https://lh6.googleusercontent.com/-s1RBmDbjbg0/T4BTZNVFTOI/AAAAAAAAFSk/p0MODcM3E5o/s640/SDC15727.JPG

This summer started by giving her a damn good wash
Then into the garage and bonnet off and started stripping bits for pulling the engine.
https://lh3.googleusercontent.com/-QfW3ykgzIeg/UD8yD6N8quI/AAAAAAAAF8U/fuZTvY3XAD0/s640/IMG_6965.JPG

First problem, UK spec 7th gens have these STUPID security cover things on the ECU to stop average joe from playing around with it.
https://lh6.googleusercontent.com/-49I87FLUDQQ/UD8x-TjpyHI/AAAAAAAAF8M/K4KGY_923xI/s640/IMG_6966.JPG

Made out of 2mm steel plate welded together, wtf Toyota?
https://lh4.googleusercontent.com/-6E7SF7jp3PE/UD8ywKpoHiI/AAAAAAAAF8o/XFMXlVQ7A-c/s640/IMG_6967.JPG

Some delicate use of a dremel and a few cuttting discs later and;
https://lh6.googleusercontent.com/-VnAYBD0JpS8/UD8zCBT6ccI/AAAAAAAAF84/AfRPyI_G83A/s640/IMG_6969.JPG

https://lh5.googleusercontent.com/-NijDYx8DdFE/UD8zkYMI6PI/AAAAAAAAF9I/_lhaU004Q_g/s640/IMG_6971.JPG

Preliminary inspection of the bores (No. 3 cylinder - through intake manifold)
All looks very good for 100k
https://lh4.googleusercontent.com/-H3I7RY59qaw/UD80LJXYzqI/AAAAAAAAF9o/F1Kenu9XThQ/s640/IMG_6986.JPG

Intake manifold and bits removed.
https://lh5.googleusercontent.com/-xVC4ey6U_vg/UD80pXnoQ4I/AAAAAAAAF94/eRbTTjoInnc/s640/IMG_6987.JPG

Where you have to put the A/C compressor when pulling a 1zzfe
https://lh4.googleusercontent.com/-52-0JEuRVzE/UD81GG8kEHI/AAAAAAAAF-I/_tNGCo5AitU/s640/IMG_6988.JPG

Engine wiring loom and clutch slave cylinder wrapped up and draped out the way over the wing
https://lh6.googleusercontent.com/-oT4hdnBuBxg/UD81BlA82bI/AAAAAAAAF-A/s56zr8mgYwU/s512/IMG_6989.JPG

Hordes of room under here to farnagle the engine out, much more than i thought possible.
https://lh4.googleusercontent.com/-Fj9wwP25A3A/UD82EoGCsDI/AAAAAAAAF-k/fhrCP7lIa8o/s640/IMG_6991.JPG

Almost an embarassing accident, remember to remove the earth cable! :biggthumpup:

https://lh5.googleusercontent.com/-VJO01ZH-8Gc/UD817PPl-BI/AAAAAAAAF-c/NhqybzynKnE/s640/IMG_6992.JPG

And with the aid of an engine crane and two mates...
https://lh3.googleusercontent.com/-U8DDqDgf5iA/UD828vhRx6I/AAAAAAAAF-4/7vNIr8DI0hM/s640/IMG_6994.JPG

Every garage should have one of these, a 5' 3" Chinese mate with a passion for getting as filthy as possible working on a car. Great for sticking in small spaces!
https://lh6.googleusercontent.com/-waCxAab2IU0/UD83AQTJb_I/AAAAAAAAF_A/rY2w52OdEzY/s640/IMG_6995.JPG
https://lh4.googleusercontent.com/-5vuHoYn7gps/UD83oinOZaI/AAAAAAAAF_M/qKu8wiEtMWQ/s640/IMG_6996.JPG

Also a mate who's 6'2" and 3' across at the shoulders and built like the proverbial! He and I can easily lift the engine and 'box between us (I'm 6' 4" and about 195lbs)
https://lh4.googleusercontent.com/-cRv8-mwrMow/UD83xd3rDdI/AAAAAAAAF_U/opf-TIFohOo/s640/IMG_6997.JPG

Stipping the engine - 240v impact driver is a beast and pulled off the crank pulley bolt in about half a second!
https://lh6.googleusercontent.com/-4LGpRQfmpgs/UD84xvQw-BI/AAAAAAAAF_o/xz6_GzceR6I/s640/IMG_6999.JPG
https://lh5.googleusercontent.com/-tlPnUTSsz9Y/UD84x2zm8vI/AAAAAAAAF_s/qHLKmhDkfgE/s640/IMG_7000.JPG



Will upload more photos shortly as and when they upload, watch this space!

T-spoon
08-30-2012, 03:30 PM
Oh this is fresh and horrible in my mind. Me and Joel (sloceli) just pulled the oil decimating 1zz out of my wife's MRS and tossed in another used lump. It was meant to be an easy job but we had to tear down the "newer" motor and clean carbon deposits off the pistons that locked the crank up!

Looks good, and yes luckily it's a very light engine :)

Luni
08-31-2012, 04:19 PM
A few things if you dont mind.

1) Smaay does this the hard way. I honestly have no idea why youd even want to mess around with the intake manifold, the radiator, and wiring harness.

Smaay has more experience working on these things overall than anyone else on this board, but Ive personally replaced my 2zz in my 7th gen, and I pulled it the way donteatbugs on here told me to and after reading how Smaay does it, its WAY easier, I promise.

With that said, the only real way it differs is, leave the wiring harness attached (its a lot easier to connect up outside of the engine bay), and dont pull out the radiator. Theres no reason to remove it. Also, you can swing the AC compressor up and over and put a towel or blanket down and it can rest on the passenger side headlight so its OUT of the way. And you can put the clutch slave cylinder up on the windshield out of the way, but leave it connected as well.

Alucard7002
08-31-2012, 09:39 PM
A few things if you dont mind.

1) Smaay does this the hard way. I honestly have no idea why youd even want to mess around with the intake manifold, the radiator, and wiring harness.

Smaay has more experience working on these things overall than anyone else on this board, but Ive personally replaced my 2zz in my 7th gen, and I pulled it the way donteatbugs on here told me to and after reading how Smaay does it, its WAY easier, I promise.

With that said, the only real way it differs is, leave the wiring harness attached (its a lot easier to connect up outside of the engine bay), and dont pull out the radiator. Theres no reason to remove it. Also, you can swing the AC compressor up and over and put a towel or blanket down and it can rest on the passenger side headlight so its OUT of the way. And you can put the clutch slave cylinder up on the windshield out of the way, but leave it connected as well.

I'm in no rush to do this, I've got 2 weeks to do it. I'm at home with the folks and I have a 2nd car. So in other words I can take it easy and do things slowly but surely.

This is my first time ever working on a 7th gen, and yes I just dived into the deep end and pulled the engine. I hadn't even done the brakes or serviced it properly since buying it as at my old house I had no driveway.

I agree with the wiring harness but the A/C compressor has different hoses on the 1zzfe and makes it physically impossible to put it anywhere except where I have. Clutch slave cylinder was not a problem.

Amongst other things I've been overhauling brake calipers and waxoiling/shutzing the underside of the car. Radiator take 10 mins to remove and allowed me to treat the subframe for a bit of surface rust.

I'm about to upload a load of photos of this week, I started on Monday morning so 6 days worth of work in one go. Just got the engine back together this evening and hopefully dropping it in tomorrow in time for and evening test drive. Fingers crossed!

Alucard7002
08-31-2012, 09:59 PM
Update time.

Mmm 100k of cheap oil being chucked in I assume?
https://lh5.googleusercontent.com/-_MUShdJNMBo/UD853zViawI/AAAAAAAAGAM/jVPZ7HTCVeM/s640/IMG_7003.JPG

https://lh6.googleusercontent.com/-zqf9t9CQY8s/UD86HMsyWtI/AAAAAAAAGGQ/sGw9RBmWy8E/s640/IMG_7004.JPG

Yet more varnish but no sludge here
https://lh4.googleusercontent.com/-6dT4KVNwMF8/UD872aZnPvI/AAAAAAAAGBM/sZN69Fv_KTc/s512/IMG_7010.JPG

Little issue with me being a stingy B****d and I stripped two head bolts :blueupset:
https://lh3.googleusercontent.com/-mSD8E8L-wP0/UD891b4eegI/AAAAAAAAGCM/9GzzusGzeJA/s640/IMG_7017.JPG

I welded on two M12 10.9 grade bolts in an attempt to undo them - nope!
https://lh6.googleusercontent.com/-Hy1Lp44eJTY/UD898wvDaYI/AAAAAAAAGCU/DgufnRsXqDY/s640/IMG_7018.JPG

Ended up drilling the head off both of them
https://lh5.googleusercontent.com/-FC6l1c_Nw-Q/UD8-JqDfFBI/AAAAAAAAGCc/OXMkf5JMQmQ/s512/IMG_7019.JPG

https://lh6.googleusercontent.com/-zNBFSXg_3cU/UD8-ocMVfUI/AAAAAAAAGCw/ZEzPIQREUQM/s640/IMG_7021.JPG

Thankfully once the tension was released the remaining piece just unscrewed by hand :cool:

https://lh6.googleusercontent.com/-KW10b3TFwUw/UD8_BzMHg4I/AAAAAAAAGC4/s7owxbeZ_ds/s640/IMG_7022.JPG

Left these well enough alone, still plenty of cross hatching left to seat new rings, especially as the middle ring is cast iron not chromed.
https://lh5.googleusercontent.com/-M1w4wgjm7PQ/UD8_OEqxGCI/AAAAAAAAGDA/bYGE9dt2Z3M/s640/IMG_7023.JPG

Paint stripper works a treat for de coking/carbonising bits of engine
https://lh3.googleusercontent.com/-b12qPXPlTkI/UD8_2DrzN_I/AAAAAAAAGDU/L3HH3xikhPg/s640/IMG_7025.JPG
https://lh3.googleusercontent.com/-2MPeWwTf67U/UD9Al5ZIW8I/AAAAAAAAGDw/q_vBRmYuPyQ/s640/IMG_7028.JPG

More sludge and varnish
https://lh5.googleusercontent.com/-jUOptnlMetM/UD9A1T4YNcI/AAAAAAAAGD4/1YL4tf5h_is/s640/IMG_7029.JPG

Shells on 1,2 & 3 looked fine for 100k
https://lh5.googleusercontent.com/-ESI12LpvZ-Q/UD9A--x6_nI/AAAAAAAAGEA/E6ROigMHqUU/s640/IMG_7030.JPG
https://lh3.googleusercontent.com/-HO7OhyNbSrA/UD9BJsmx_SI/AAAAAAAAGEI/i9zjvopZJAc/s640/IMG_7031.JPG

Unsticking piston rings, the easy way! Pot of paint stripper and leave for 5 mins, all of them popped out no problem after that
https://lh5.googleusercontent.com/-ySpH8BrDv54/UD9BkjNntUI/AAAAAAAAGEU/GUSUKMqELKU/s640/IMG_7032.JPG
https://lh4.googleusercontent.com/-tIj519b7z44/UD9B5S0LxYI/AAAAAAAAGEc/_ncpm0M5r5k/s640/IMG_7033.JPG
https://lh5.googleusercontent.com/-pcdW36OlFzE/UD9B9gX3QPI/AAAAAAAAGEk/b2gpLjzH-v8/s640/IMG_7034.JPG

Straight out of the paint stripper, just washed in hot soapy water. (oiled after they were dry)
https://lh3.googleusercontent.com/-Swv8vfcZAbc/UD9CY8Y0KvI/AAAAAAAAGEs/1P7N24m7I80/s640/IMG_7035.JPG

One new hole each side, PITA to drill but managed in the end, also enlarged the two existing holes
https://lh6.googleusercontent.com/-RkhhE7t_Tf8/UD9Cgoy4_BI/AAAAAAAAGE0/O1M-IihK7UQ/s640/IMG_7036.JPG

Also cut two slots on each side of the piston in the cut out, all to help with oil drainage. Similar to the revised piston design issued by Toyota in '05
https://lh6.googleusercontent.com/-OmDKEbPmNGc/UD9D_vtMBuI/AAAAAAAAGFc/qTyjJamhQUI/s640/IMG_7041.JPG

Cleaned as much oil muck and sludge off of as many parts I dared use paint stripper and petrol on.
https://lh4.googleusercontent.com/-iRgfux08xjk/UEEjqkiojOI/AAAAAAAAGHM/NZ56RejNb48/s640/IMG_7051.JPG
https://lh3.googleusercontent.com/-yGgpWqilc7M/UEElEZzo3PI/AAAAAAAAGHw/0DD4mE5WB08/s640/IMG_7056.JPG

Big Jon was useful once again!
https://lh5.googleusercontent.com/-Dpz0lZYjXeA/UEEka8Q0WmI/AAAAAAAAGHc/TtGpXiUgTZU/s512/IMG_7055.JPG

I'll upload more in a mo after they finish uploading to my hosting site

Alucard7002
08-31-2012, 10:36 PM
No. 4 big end bearing was shot though
https://lh6.googleusercontent.com/-5lHIMZousw8/UEEqEJSMdFI/AAAAAAAAGKU/Pfqjk4sYbKI/s640/IMG_7078.JPG

Scored to hell but thankfully the crank is still ok and within spec. no noise from this bearing though, even running on 5/30. Can't imagine what i'd have done if this had spun :eek4:

New set fitted sharpish!

Kept the old rings as souvineers! Now every time I look in the mirror I should see no blue smoke and the reason why!
https://lh6.googleusercontent.com/-_lOOJEbmmhI/UEEo5pfeyaI/AAAAAAAAGJw/bHVWLDuR7XQ/s640/IMG_7072.JPG

Oh and I sheared a cam cap bolt, thank you BGB for not being clear you meant all small cam caps not just No.3 in the tightening sequence is 13nm, obvsiously mis-read, and rectified the mistake.

https://lh3.googleusercontent.com/-8oBaURrAK5k/UEEsnl4zjQI/AAAAAAAAGL0/0LgWYZtVxUI/s512/IMG_7090.JPG

Thankfully another easy fix.

Exterior

Washed then clayed

Debadged the rear end and "Toyed" with this idea for a moment or two...
https://lh4.googleusercontent.com/-MKiqSmZ59Yk/UEEqkgsEQvI/AAAAAAAAGKc/aknErSubehs/s640/IMG_7079.JPG
https://lh3.googleusercontent.com/-jkULDR8l3fk/UEEqprMDAsI/AAAAAAAAGKk/zeFcpYV3SO0/s640/IMG_7080.JPG

Brakes, Electrocleaned/de-rusted and painted in a few coats of "tractor enamel".
https://lh5.googleusercontent.com/-rPeV7TxU1t8/UD9ACVJcCaI/AAAAAAAAGLI/fd-icxrLZxY/s640/IMG_7026.JPG
Electro cleaning bath
https://lh6.googleusercontent.com/-wuG6hgfHZ6U/UD9AdNi2lyI/AAAAAAAAGDk/6SnGNKODfsc/s640/IMG_7027.JPG
Straight out the bath, all rust has been removed by either blasting off by hydrogen and oxygen bubbles or reduced to Iron III oxide (Black mill scale type stuff)
https://lh5.googleusercontent.com/-ZIWlbq_7c1s/UD9DW_OaoNI/AAAAAAAAGLU/vv-zLgtxsMw/s640/IMG_7037.JPG
https://lh3.googleusercontent.com/-hVBi0Cvdk0k/UD9DPZvyGuI/AAAAAAAAGFA/7CeRjLkYt_4/s640/IMG_7038.JPG
Quick jet wash
https://lh3.googleusercontent.com/-nybqJu9jT94/UD9DyvXtWsI/AAAAAAAAGFU/w0xchpW7R8w/s512/IMG_7039.JPG
https://lh6.googleusercontent.com/-G9CyYE7Kt5M/UD9EYplA5gI/AAAAAAAAGFk/mQWjqnVtr_Q/s512/IMG_7040.JPG
Light wire brush to remove flash rust and Iron III oxide
https://lh6.googleusercontent.com/-gl1R33sxOM8/UEEintYKySI/AAAAAAAAGGc/iUP4d96OaHI/s640/IMG_7046.JPG
Used Mum's oven when she wasn't looking to harden the paint really well
https://lh6.googleusercontent.com/-Sn9PszOGSKY/UEEopsGKhyI/AAAAAAAAGJk/ixzCKPYwrFQ/s640/IMG_7071.JPG
Shiny Shiny! Got to be extra Powah's for having calipers like this!
https://lh6.googleusercontent.com/-Mi7t4NoK1fY/UEEpoJ7I69I/AAAAAAAAGKA/gvjcTSA65ZI/s640/IMG_7076.JPG
https://lh3.googleusercontent.com/-KY9BAXSwdNQ/UEEpzvyv5WI/AAAAAAAAGKI/t9lyd4Dyyz0/s640/IMG_7077.JPG

New discs pads and shoes
https://lh3.googleusercontent.com/-96RxYV_ux1A/UEErT7S26QI/AAAAAAAAGK4/21Xgs3MIZ64/s640/IMG_7084.JPG
https://lh5.googleusercontent.com/-LrPRlPkLcko/UEErdm7dVEI/AAAAAAAAGLA/yq8IU-qfdDQ/s640/IMG_7085.JPG
https://lh4.googleusercontent.com/-hvJnk9DmKkQ/UEErj11_YeI/AAAAAAAAGLM/vrP1irQiTss/s640/IMG_7086.JPG

F***ing fiddly R-clips, almost lost them twice!
https://lh3.googleusercontent.com/-h8Cb4JxTANU/UEEq1ZO4voI/AAAAAAAAGKw/yCWW8ZSz0e4/s640/IMG_7081.JPG

Plan is tomorrow fit the engine, test it, bleed brakes FIRST, then drive it. Wash the car, polish the living crap out of it as the paintwork is in poor shape. Dad's got a DA and that does a good enough job eventually to be presentable as a daily driver/toy

Let you all know tomorrow evening how it went!

Alucard7002
09-01-2012, 07:41 PM
Brakes done, engine in and It Started!

15 seconds of cranking with the injectors un plugged and oil pressure light goes out.

Started after another 15 seconds of cranking to prime fuel rail

Ran sweet as a nut but the accessory belt tensioner need replacing. Bearings are shot and warbling their merry symphony.

Torque up hub nuts and plonk her back on her feet for a quick spin then bonnet & bumper on and a proper test drive.

Luni
09-01-2012, 09:52 PM
That sucks about the tensioner needing replacing. That is a crappy part to replace. You gotta pull 2 of your 4 mounts and jack the engine up on that side to get the thing out.

Alucard7002
09-01-2012, 10:07 PM
That sucks about the tensioner needing replacing. That is a crappy part to replace. You gotta pull 2 of your 4 mounts and jack the engine up on that side to get the thing out.

Yup, annoyed as it would have been a piece of piss to whack a new one on when engine was out. Oh well, least it's not an engine out job.

Just taken it for a spin, new clutch is amazingly light, old friction plate must have been well and truly rusted on the splines. Fully synth gearbox oil is a dream too, silky smooth compared to before ( even then it was a nice change!)

Jobs to do now,

Replace tensioner
Oil change after 260 mile trip this coming week. (and again 1000k later)
Full valet & detail
Get it MOTed

Hope she burns no oil!

Cheers for now

Lonestag
09-02-2012, 06:42 PM
Fun read!
Did a good job on those brakes, I could take a page from your book there!

MCcelica
09-04-2012, 06:07 AM
Fun read!
Did a good job on those brakes, I could take a page from your book there!

Agreed. I was thinking that your methods were a bit unorthodox, but I like the tractor enamel idea.

Smaay
09-06-2012, 05:06 PM
yes the cylinder walls still looked good, but please tell me you still honed them. if you didnt, you are going to burn oil. you MUST hone the walls using new rings.

Alucard7002
09-06-2012, 07:09 PM
yes the cylinder walls still looked good, but please tell me you still honed them. if you didnt, you are going to burn oil. you MUST hone the walls using new rings.

Yes after further research and asking around local machine shops I went ahead and honed them.

Just finished a 300 mile trip, going easy, not a drop burned. (same trip before rebuild burnt 2.5 litres!)

Need new tensioner still and oil change. Then she's done!

Well pleased with the result and the cost of doing so.

Luni
09-07-2012, 12:30 AM
Dont put off that tensioner too much longer man. If that thing goes out or locks up and causes you to throw a belt, you will overheat and could damage your engine. Your waterpump is driven by that serpentine belt.

Alucard7002
09-07-2012, 09:26 AM
Dont put off that tensioner too much longer man. If that thing goes out or locks up and causes you to throw a belt, you will overheat and could damage your engine. Your waterpump is driven by that serpentine belt.

Yup ordered one today, going to fit it when it arrives. Using the Rover until then.

I kept a careful eye/ear out for a "thump" and the charging light coming on!

Good news too is that I averaged 38mpg (UK mpg) on the trip. Not bad at all for a freshly rebuilt engine!

Alucard7002
09-30-2012, 07:04 PM
Long overdue update. Swapped the tensioner out, not a bad job to be fair. managed with two scissor jacks in the car park!

Oil change done and brake shoes re-adjusted (now locks the wheels easily!)

Last job is a full wheel alignment - badly needs doing as I just guessed the camber on the front end so I have no idea what it's running.

Good news is it's lost almost no oil since the rebuild. obviously I expect some loss due to new rings.

Oil was very very clean which surprised me a little but not complaining!

Total cost for new rings, bearings, head bolts, brake discs/pads/shoes and two new tyres...

Just under 500 pounds roughly = $800
car cost 1800 quid = $2900

should be good for at least another 50k before I expect to have to replace springs/dampers and suspension bushes

All in all a relatively cheap toy car! :)