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Thread: Daihatsu Copen Engine Rebuild

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    Post Daihatsu Copen Engine Rebuild

    Alhumdulillah we at our garage have completed a rebuild of the engine and Head of Daihatsu Copen in 5 days. Today was the initial test drive and by the grace of Allah Paak, the rebuild has been flawless. The car had broken valves, damaged head and valve seals and damaged pistons. The damage is pretty evident in the pictures. There is a bit of information and some learnings which I will share in the mechanical/electrical forum.
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    When KNOWLEDGE speaks.... WISDOM listens.

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    excellent work!!!!
    "Stand by your glasses steady and drink to your comrade's eyes.
    Here's a toast to the dead already and hurrah for the next to die."

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    what happened to the engine btw hasn't this got a timing chain?
    work looks promising, subscribed
    If everything is coming your way, you're in the wrong lane!

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    Quote Originally Posted by arzaam.bhatti View Post
    what happened to the engine btw hasn't this got a timing chain?
    work looks promising, subscribed
    The engine had internal fatal failure. Exhaust valves broke in one cylinder while many valves were bent in others. The spark plug had broken into pieces as piston crashed into the valves. It is evident that engine was over revved at high speeds. It does have a timing chain but we took if off and pic was taken after. The tappets are all auto adjusted in this engine.
    When KNOWLEDGE speaks.... WISDOM listens.

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    Quote Originally Posted by Marschall View Post
    excellent work!!!!
    do you mean by Excellent Work the guy who did this to the engine or who fixed the engine?? I will take the positive so you are welcome brother. Gratitude.
    When KNOWLEDGE speaks.... WISDOM listens.

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    Quote Originally Posted by the_vitzician View Post
    The engine had internal fatal failure. Exhaust valves broke in one cylinder while many valves were bent in others. The spark plug had broken into pieces as piston crashed into the valves. It is evident that engine was over revved at high speeds. It does have a timing chain but we took if off and pic was taken after. The tappets are all auto adjusted in this engine.
    Over rev how? Did the rev limiter not work?
    "Being between arabs, you call it "Jimmss Yukaan Sagheer", or GMC yukon." - Xulfiqar.

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    Quote Originally Posted by supraman2jz View Post
    Over rev how? Did the rev limiter not work?
    Over-Boosted Motor Or Boost Under LEAN.....Can Be Anything
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    Quote Originally Posted by supraman2jz View Post
    Over rev how? Did the rev limiter not work?
    Quote Originally Posted by SER_GTR View Post
    Over-Boosted Motor Or Boost Under LEAN.....Can Be Anything
    The ECU only has an electronic rev limiter - meaning it can hold the rpm by removing fuel and spark.

    It however cannot prevent a mechanical rev limiter - meaning if you shift from 4 to 2 at 120 km/h and pop the clutch - engine spins to a few billion rpm and you end up with scrap metal engine. - I see this one has an automatic gearbox, I dont see how one can do a mechanical overrev without trashing the gearbox.

    That sort of valve failure you see in the picture happens from the valve being stressed, this sort of wear is accelerated by bad valve clearances which overheats the valve badly (very badly on a turbo engine). Such heat also damages the guide and lets the valve sit askew on the seat (which is poor anyway because of tight clearance). Repeat this a few billion times and you essentially are bending the valve poppet in different directions on every work cycle. - The end result the valve head lets go from where its welded to the stem (congratulations, your valves and pistons made tiny baby pieces of valve and pistons)

    I would scrap that cylinder head - it will create bad spark knock in that cylinder, the piston too. By the colour of the engine varnish I think the owner was using low quality dino oil in there (bad juju for turbocharged engine)
    ZRS - Zulfiqar Racing Systems ..... - professionals at work - at crackwheels.com

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    what is the engine name/code
    haters gonna hate, potatoes gonna potate

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    Quote Originally Posted by the_vitzician View Post
    The engine had internal fatal failure. Exhaust valves broke in one cylinder while many valves were bent in others. The spark plug had broken into pieces as piston crashed into the valves. It is evident that engine was over revved at high speeds. It does have a timing chain but we took if off and pic was taken after. The tappets are all auto adjusted in this engine.
    If the tappets are auto adjusted, does it mean clearances can't be set?

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    Quote Originally Posted by Xulfiqar View Post
    The ECU only has an electronic rev limiter - meaning it can hold the rpm by removing fuel and spark.

    It however cannot prevent a mechanical rev limiter - meaning if you shift from 4 to 2 at 120 km/h and pop the clutch - engine spins to a few billion rpm and you end up with scrap metal engine. - I see this one has an automatic gearbox, I dont see how one can do a mechanical overrev without trashing the gearbox.

    That sort of valve failure you see in the picture happens from the valve being stressed, this sort of wear is accelerated by bad valve clearances which overheats the valve badly (very badly on a turbo engine). Such heat also damages the guide and lets the valve sit askew on the seat (which is poor anyway because of tight clearance). Repeat this a few billion times and you essentially are bending the valve poppet in different directions on every work cycle. - The end result the valve head lets go from where its welded to the stem (congratulations, your valves and pistons made tiny baby pieces of valve and pistons)

    I would scrap that cylinder head - it will create bad spark knock in that cylinder, the piston too. By the colour of the engine varnish I think the owner was using low quality dino oil in there (bad juju for turbocharged engine)
    Brother I agree with the reasoning you have provided. The transmission on the car is actually trip-tronic type. You can shift to manual mode any time while you are driving in auto mode and over ride it and vice versa. So what I have assessed is that some how at high speeds a shift was made to manual mode and the guy (friend of the client driving at that time) was not quite familiar to a semi- auto transmission. He somewhere shifted a few gears low while he had to shift up. The engine rev limiter is at 8500 RPMs so one can imagine the next part of the drama easily considering that once you sit on the wheels of this car you do get an adrenaline rush to rev it.
    When KNOWLEDGE speaks.... WISDOM listens.

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    Quote Originally Posted by the_vitzician View Post
    Brother I agree with the reasoning you have provided. The transmission on the car is actually trip-tronic type. You can shift to manual mode any time while you are driving in auto mode and over ride it and vice versa. So what I have assessed is that some how at high speeds a shift was made to manual mode and the guy (friend of the client driving at that time) was not quite familiar to a semi- auto transmission. He somewhere shifted a few gears low while he had to shift up. The engine rev limiter is at 8500 RPMs so one can imagine the next part of the drama easily considering that once you sit on the wheels of this car you do get an adrenaline rush to rev it.
    the manual mode of the gearbox will never allow an overrev - its built into the logic of the control unit. e.g. if you are doing 120 km/h and suddenly start to shift to 1st gear - the unit will not allow, it will only allow the engine redline and bounce off the limiter.

    The valve breaking is a stressed valve issue - usually happens from overheated valve poppet and worn guide

    btw - there is no adrenaline rush in this car.
    ZRS - Zulfiqar Racing Systems ..... - professionals at work - at crackwheels.com

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    was this head replaced??
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    y not a kabli replacement?

    this engine will never get the compression it had after the rebuild
    Life is short and very unpredictable just like a Quarter mile .....

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    Quote Originally Posted by hash4u View Post
    y not a kabli replacement?

    this engine will never get the compression it had after the rebuild
    Brother we did a 8 hour non stop static running test of the engine after the rebuild. Then it was driven a total of 1100 Kms in the next 15 hours. The engine was primarily kept running even during stop overs. We achieved the Combined mileage (Urban & Highway) of 15.3 Km/Liter. The reported factory combined mileage is at 15.6 Km/Liter. And we did not replace the head either. It was the same original head of the engine.
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    Quote Originally Posted by the_vitzician View Post
    Brother we did a 8 hour non stop static running test of the engine after the rebuild. Then it was driven a total of 1100 Kms in the next 15 hours. The engine was primarily kept running even during stop overs. We achieved the Combined mileage (Urban & Highway) of 15.3 Km/Liter. The reported factory combined mileage is at 15.6 Km/Liter. And we did not replace the head either. It was the same original head of the engine.
    How You Get Rid Of Those Pitted Damaged Spots Near Spark Plug And Valve Seat Being Put By Piston And Broken Valve Deeply Into Certain Angle You Can't Shave It Off.....
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    Quote Originally Posted by Xulfiqar View Post
    the manual mode of the gearbox will never allow an overrev - its built into the logic of the control unit. e.g. if you are doing 120 km/h and suddenly start to shift to 1st gear - the unit will not allow, it will only allow the engine redline and bounce off the limiter.

    The valve breaking is a stressed valve issue - usually happens from overheated valve poppet and worn guide

    btw - there is no adrenaline rush in this car.
    Never Hear Of Any Such Adrenaline Rush In Coupen.....Just A Good Small Ride For Some FUN....!
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    Quote Originally Posted by SER_GTR View Post
    How You Get Rid Of Those Pitted Damaged Spots Near Spark Plug And Valve Seat Being Put By Piston And Broken Valve Deeply Into Certain Angle You Can't Shave It Off.....
    Brother does this look like a result of a misfiring, vibrating, low compression no good engine?
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    Just to add, copen in particular when shifting from auto to manual or down shifting the car makes selection automatically.

    To avoid over Rev etc. For example if ur crusiing at 80-90-100 km/h and you shift to manual the car would shift to 3 or 4 you cannot take it to 1st or second gear manually at those speeds

    And the car is prone to overheating aswell.

    Had one in the family it's real fun but it's a useless car for anything over the price of a Mehran. Plus being turbo these things are fuel eaters

    I'm glad the newly built is managing 15km/L

    Ours hardly managed 8-9km/L with a heavy foot ofcourse
    Get over the fact that Xli lacks power windows, Its an Xli because it lacks thoose features or else it would be a Gli or an Altis if had all the goodies.

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    Quote Originally Posted by the_vitzician View Post
    Brother does this look like a result of a misfiring, vibrating, low compression no good engine?
    This just a sign of a perfect fuel mixture


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