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Just update those who might be interested.
I have finally teared the engine into pieces after few months sorrow time…
As assumed, original problem was failed IMS-bearing causing main chain (between crankshaft and intermediate shaft) tension blade to break (see enclosed pictures). Loose piece of the tension blade went in between IMS sprocket and engine block punching a hole in the block as sown before.
Had some luck also, since even timing had slipped on both cylinder blocks, and all exhaust valves had touched piston heads, there was only one visually bent exhaust valve. Took the cylinder heads to local workshop for checking, and they discovered that totally 5 exhaust valves need to be replaced. But not so bad (only 5 out of 12) what it could have been.
Decided to replace all moving parts inside the engine since it is in pieces. So I have ordered: both cam chains, main chain, all support and tension blades for the chains, main bearings for crank shaft, piston rod bearings, all AOS units (3 pieces), pressure bearing for clutch, ceramic IMS-bearing, full set of gaskets, etc.
Have already sent about 2800 EUR for the parts. I could have done it cheaper of course, by replacing necessary part only, but on the other hand now it will be equal to new engine (more or less) and since it was in pieces…
Still cheaper option than replacement engine. I checked prices for replacement engines as well. Engine from collision car with only 3 months warranty, driven about 100 tkm, was about 3400 EUR + new IMS-bearing = 4000 EUR. Rebuild engine with new piston rings, bearing, AOS, etc. with 1 year warranty was about 5500 EUR (old engine needed for exchange).
Hole in the engine block was welded in one of the local workshops. Went actually quite smoothly and looks good.
Been washing and cleaning the engine parts while been waiting for the ordered parts. For example most of the hydraulic lifters (or tappets) were jammed. So I needed to dismantle (not an easy task…) them and clean them properly. I hoped that I have not saved in wrong place with the hydraulic lifters??? I mean not replacing them???
Been manufacturing some special tools myself, and still need to some for piston installation. So far I have not purchased any special tools, but some normal ones available in local tools shop.
I have also bought quite many instruction books and work shop manuals.
Been very interesting project. I still have a goal to get it done before 1st of May (that is normally when the summer or spring at least starts here in Finland). I took me about one month to remove the engine from the car and dismantle it (working evening and weekends) so I am assuming that it will take maybe about two months to put it back together (more time needed for reading instructions and checking things).
So wish me luck and Happy New year to all of You
PS. I have a lot of pictures available of the project if somebody is interested to see them.
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