Well there is a common term in the market which is too much famous that ( SILVER KA ENGINE HAI YEH REBUILT NAHE HOTA IS SAY ACHA HAY KABALI ASSEMBLY DAAL LO) . These are the word's which we hear if our vehicle's engine is damaged or near dying condition. Then a new chapter open's in which the Engine identification no is changed on the Registration Book.
Keeping all of these factor's in mind I decided to rebuilt the engine of Toyota Vitz owned by my very honorable friend and Client Mr Faheem.
We Disassemble the engine and found out the Damages caused by excessive knock issue's and also the PCV line was Clogged and No PCV Ventilation was there so faced a huge build up of Engine Oil Sludge On all part's.
Problem's Detected when Engine was Disassembled.
Problem's detected in cylinder Block.
1: Oil Ring's were Gone The Induction and Compression Ring's were fine.
2: Oil Pump Assy Was fine
3: Piston's were scratched from the side Wall's.
4: Crank Bearing's were all fine.
5: Crank Shaft was Fine.
6: Cylinder Bore need's to be polished up.
7: Connector Rod's were fine No damage at all.
Problem's Detected in Head Assy
1: Valve seal's were Worn Out
2: Valve Guide's were loose.
3: Valve Seat's were fine but need to be polished.
4: Both CAM Shaft's were fine no damage's at all.
5: Head Face Was Perfect.
Part's We Replaced.
As The Piston's were not on the good condition we Decided to Install New Piston's and rebore the existing Cylinder .
1: New Piston's of 0.50
2: Cylinder Was Bored according to the New piston size.
3: New Piston Ring Set.
4: OEM Head Gasket
5: Gen Kit Set for the whole engine
6: Brand New Head Assy Bolt's
7: Old Crank Bearing's were used as they were absolutely fine.
8: Brand New OEM Valve's 0.25
9: New Valve Seal's
10: Valve guide's were Grind-ed with the oversize valve's.
11: Changed the VVTi Cam Gear as the OLD One was Clogged with Oil Sludge. Tried to service it but it was waste of time.
other stuff chaged
1: Brand New Oxygen Sensor.
The total Cost of this rebuild was 30 % lesser than the Price of Kabuli Assembly So I am Very satisfied with the Rebuild. has Completed it initial Break up and the engine now much smoother and powerful again.
Total Rebuild Cost was 42000/-Pkr and additional 13500/-Pkr For the New Oxygen Sensor.
I had given the link to the rebuild Video below