Mk1 Pi engine rebuild

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M5driver
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Mk1 Pi engine rebuild

#1 Post by M5driver » Thu Jan 03, 2019 9:20 pm

After many years of service the original engine for my Mk1 Pi is out for a rebuild. The reason being it was rather smokey and leaking oil and probably down on power.So far the rocker shaft has been removed and dismantled.
The attachment P1030172.JPG is no longer available
If you can see most of the flats for the oil feed holes have worn away. So this needs replacing. After wiping the shaft down there were also some ridges where the rockers ran . Also all of the rockers themselves are wearing through the hardened surface. these will also be replaced.
P1030172.JPG
All the head nuts have been removed and in the process two of the studs came out as well. As far as I am aware this head has never been off since Triumph put it together. I have had a look at the push rods and the face bearing against the follower has worn equally I must say they are not bad for an engine that has covered around 115000 miles.



The next job is to get the head off the block and assess the state of the valves, seats and guides. When this has been done I can then get the reminder of the engine on the stand for the rest of the disassembly.
The attachment P1030170.JPG is no longer available
Last edited by M5driver on Wed Jan 23, 2019 12:53 pm, edited 2 times in total.
Chris Lennard Mem 1906
Triumph 2.5pi MK1 1969 Damson, tan interior
TRiumph 2.5pi MKII 1972 Mallard, black interior
BMW E34 M5 LE 47/50 Orinoco Green
VW Golf mk6 Bluemotion Black

Tinsmith_Skippy
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Re: Mk1 Pi engine rebuild

#2 Post by Tinsmith_Skippy » Fri Jan 04, 2019 5:27 pm

Hello Chris happy new year to you. Looking forward to reading future posts on your engine rebuild. I’m going to have to rebuild my Pi engine as wel. It was well seized up, had to knock 3 seized pistons out off the block. Probably going to be a rebore than a honing procedure due to rust pitting in the liners. All the best.
Ross Taylor & Paul Taylor
Member: 7644 & 7644A

M5driver
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Re: Mk1 Pi engine rebuild

#3 Post by M5driver » Sun Jan 13, 2019 8:16 pm

<r>The head has been removed with much heaving and hoeing. My back doesn't like it. But it came off without too much brute force. The valves and springs have been removed have been removed. I have checked the valve stem movement in the guide. All the exhausts move excessively the inlets are not so bad. But all will be replaced I think.<br/>

<ATTACHMENT filename="P1030184.JPG" index="0"><s>
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</e></ATTACHMENT>

All a bit rich but the car was being moved around the yard when the engine was last run.<br/>
<br/>
All the valves out the usual carbon build up.<br/>

<ATTACHMENT filename="P1030190.JPG" index="2"><s>
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Here is a closer shot. Not bad considering its the first time apart.<br/>

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Finally a shot of the bores not a great one the lighting is not the best.<br/>

<ATTACHMENT filename="P1030187.JPG" index="1"><s>
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</e></ATTACHMENT>

The next task is to get the engine onto my stand. A crane is required and I may have to borrow one. Have a busy week at work so not much can be done now for the next 6 days.</r>
Chris Lennard Mem 1906
Triumph 2.5pi MK1 1969 Damson, tan interior
TRiumph 2.5pi MKII 1972 Mallard, black interior
BMW E34 M5 LE 47/50 Orinoco Green
VW Golf mk6 Bluemotion Black

M5driver
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Re: Mk1 Pi engine rebuild

#4 Post by M5driver » Sun Jan 13, 2019 8:19 pm

Sorry the pictures did not load up. Damn computers.
The attachment P1030184.JPG is no longer available
The attachment P1030186.JPG is no longer available
The attachment P1030190.JPG is no longer available
P1030184.JPG
Chris Lennard Mem 1906
Triumph 2.5pi MK1 1969 Damson, tan interior
TRiumph 2.5pi MKII 1972 Mallard, black interior
BMW E34 M5 LE 47/50 Orinoco Green
VW Golf mk6 Bluemotion Black

M5driver
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Re: Mk1 Pi engine rebuild

#5 Post by M5driver » Wed Jan 23, 2019 1:01 pm

Well have tried editing the posts to put the pictures back in no luck I can only seem to post one per reply.

Anyway now the timing gear is off cam and followers out. No signs of wear to the cam or followers. the timing chain is worn so is the tensioner, also the crank sleeve was turned around due to being scored by the oil seal. I have seen this many times in the past, so will be replaced.

Anyway here is a pic of the worn rockers again.
P1030171.JPG
Chris Lennard Mem 1906
Triumph 2.5pi MK1 1969 Damson, tan interior
TRiumph 2.5pi MKII 1972 Mallard, black interior
BMW E34 M5 LE 47/50 Orinoco Green
VW Golf mk6 Bluemotion Black

Charles H
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Re: Mk1 Pi engine rebuild

#6 Post by Charles H » Thu Jan 24, 2019 11:42 am

Getting there Chris!
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Re: Mk1 Pi engine rebuild

#7 Post by M5driver » Mon Feb 18, 2019 11:12 am

<t>I've been quiet for nearly a month, a combination of shifts that don't fit with leisure time. Also buying parts and seeking advice. So thanks to Messrs Harvey, Shackford and Witor.<br/>
<br/>
In the last few weeks cleaning has been taking place to the reusable parts from the rocker gear, timing and rocker covers and gunking the block. This is a filthy job especially after nearly 45 years of use. <br/>
<br/>
I have also cleaned some of the valve faces and found pitting so these will be replaced. Exhausts already purchased. I'm still waiting for a friend to bring over his engine crane, I can see myself buying one. I have been made aware of a good engine reconditioner near Bedford which I will in time be in touch with for machining costs, ie flywheel refacing and balancing with the crank if they can do it, head refacing valve guide fitting and 3 angle seat cutting. I'm hoping the block just needs a hone and the crank in tolerance we shall see.<br/>
<br/>
The shopping list is growing you would be surprised at the number of fixings that are use on these engines some of which have been mislaid some of which on close inspection are worn out.<br/>
<br/>
Anyway some work to do today and then a break in Spain for the rest of the week.</t>
Chris Lennard Mem 1906
Triumph 2.5pi MK1 1969 Damson, tan interior
TRiumph 2.5pi MKII 1972 Mallard, black interior
BMW E34 M5 LE 47/50 Orinoco Green
VW Golf mk6 Bluemotion Black

Charles H
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Re: Mk1 Pi engine rebuild

#8 Post by Charles H » Tue Feb 19, 2019 11:06 am

Nice one Chris. Enjoy Spain!
Charles Harrison
Register member 3095
Folkestone
Cherry Red Mk1 2000 Rally Car
Mallard Blue 2.5PI
Sapphire Blue GT6 Mk3
Vermillion Red Spitfire 1500
Pimento Red TR6
Pimento Red Stag
Inky Blue VW Passat B5.5
Arctic Blue Jaguar XJ40

M5driver
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Re: Mk1 Pi engine rebuild

#9 Post by M5driver » Tue Feb 19, 2019 12:02 pm

Thanks Charles,

Been productive the rocker shaft is assembled with new rockers and shaft. All the other parts cleaned, assembly carried out with assembly oil, a bit like honey. Photo taken of finished article.
P1030196.JPG
Long way to go.
Chris Lennard Mem 1906
Triumph 2.5pi MK1 1969 Damson, tan interior
TRiumph 2.5pi MKII 1972 Mallard, black interior
BMW E34 M5 LE 47/50 Orinoco Green
VW Golf mk6 Bluemotion Black

M5driver
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Re: Mk1 Pi engine rebuild

#10 Post by M5driver » Fri Mar 15, 2019 4:39 pm

At Last the engine block is on the stand. So the sump came off today and the oil pump removed. It is the original cast iron type with not much wear looking at it.
The attachment P1030288.JPG is no longer available
I removed one bearing cap No3 this showed hardly any wear to the shells, I find this surprising. I also removed No5 big end there was some wear to this shell but not a great deal.

In the sludge at the bottom of the sump I found this.

And the sludge which is grey under the surface?
The attachment P1030289.JPG is no longer available
P1030288.JPG
Chris Lennard Mem 1906
Triumph 2.5pi MK1 1969 Damson, tan interior
TRiumph 2.5pi MKII 1972 Mallard, black interior
BMW E34 M5 LE 47/50 Orinoco Green
VW Golf mk6 Bluemotion Black

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