|
Costs
- The overall costs of parts were a major consideration before any work started. I
reckoned on having to spend at least £500 re-newing the timing chain and associated
parts. I never thought I would have to do any other major work as these engines can keep
going well into 200k.
- Even just doing the head gasket and timing chain was never going to be a weekend
job, even if I had the money, so, first thing was to buy another car so I could take my
time to decide exactly how I was going to tackle the work ahead. This immediately set me
back around £500 to get a Cavalier bought taxed and on the road. I should be able to get
this outlay back in a couple of months anyway.
After pricing second hand engines and re-con engines, the only sensible option
for me was to do the re-build myself. I'm not a mechanic and the thought of working on one
of these engines had always scared the hell out of me, but, I had no choice. I have done
an engine re-build many years ago so I had an idea of what was ahead.
- I needed to find someone to do the machining work. I would have liked to have
gone to someone who had already been used by another member of our club, however, not many
of us have had to go this far yet.
I first visited a machinist called Jenkins Motor Engineers based in Whitton,
just off the end of M3 in London. They are a member of FER (Federation of Engine
Manufacturers) and they seemed to be quite well known by the auto traders in the local
area. I also visited (by coincidence) another Jenkins machinist in Farnborough, local to
me. This would have been easier for me but the guy was not very interested in doing the
job, quoting stupid prices and basically trying to frighten me away by saying how much
parts cost, at one point I remember him saying something like 5 grand for a re-build ! ha,
I walked away. It turns out that both machinist's were originally owed by the same company
until they split some years ago.
I took the head,block and crank to the Jenkins in London. I was looking to have
the head welded and skimmed, the crank re-ground, block honed. Mick had given me an idea
of cost's the first time I'd spoken to him and we talked about various options. At first I
was just going to have the block honed and fit new rings, however the price for re-bore
with new pistons and rings was only about £200 more,so, I was now undecided . I left the
block with him so that he could measure up himself and make a recommendation later.
After seeking advice from Ian Marsh I decided for just the hone option, I could
ill afford to spend £200 if it was un-neccessary.
- The following table outlines the cost's to date, all prices are subject to VAT.
- Vauxhall prices are based on the Autobahnstormers negotiated club discount.
|
Description |
Part
Ref |
Qty |
Price Ea |
Sub |
|
|
|
|
|
|
|
Machining Work |
|
|
|
|
|
Weld
head |
|
1 |
£35.00 |
£35.00 |
|
Plug
Insert |
|
1 |
£15.00 |
£15.00 |
|
Skim
Head |
|
1 |
£30.00 |
£30.00 |
|
De-grease
block |
|
1 |
£10.00 |
£10.00 |
|
Skim
Block |
|
1 |
£35.00 |
£35.00 |
|
Hone
Bores |
|
6 |
£3.00 |
£18.00 |
|
Re-grind
crank & supply new bearing shells |
|
1 |
£140.00 |
£140.00 |
|
Piston
Rings |
|
6 |
£26.00 |
£156.00 |
|
Graphogen
Assembly Oil |
|
1 |
£7.00 |
£7.00 |
|
|
|
|
|
£446.00 |
|
|
|
|
|
|
|
Miscellaneous Costs |
|
|
|
|
|
Re-rubber
Oil Cooler Hoses (new price £48.45 ea) |
90409241 |
2 |
£18.00 |
£36.00 |
|
Inlet
manifold 'o' rings (vaux price 2.57ea) |
90324467 |
6 |
£0.30 |
£1.80 |
|
Engine
Block Paint |
|
1 |
£6.00 |
£6.00 |
|
Exhaust
Manifold Paint |
|
1 |
£6.00 |
£6.00 |
|
Primary
and secondary timing chains(Ian Marsh) |
|
1 |
£75.00 |
£75.00 |
|
|
|
|
|
£124.80 |
|
|
|
|
|
|
|
Vauxhall Original Parts |
|
|
|
|
|
|
|
|
|
|
|
OIL
PICK UP GASKET |
90323494 |
1 |
£0.16 |
£0.16 |
|
SUMP
DRAIN PLUG WASHER |
11023582 |
1 |
£0.10 |
£0.10 |
|
SUMP
GASKET |
90354211 |
1 |
£21.17 |
£21.17 |
|
FRONT
CRANKSHAFT OIL SEAL |
90352108 |
1 |
£10.29 |
£10.29 |
|
REAR
CRANKSHAFT OIL SEAL |
90180524 |
1 |
£22.74 |
£22.74 |
|
GEARBOX
INPUT SHAFT 'O' RING |
90446393 |
1 |
£1.66 |
£1.66 |
|
GEARBOX
INPUT SHAFT OIL SEAL |
90288050 |
1 |
£7.91 |
£7.91 |
|
GEARBOX
OUTPUT SHAFT OIL SEAL |
90288049 |
1 |
£6.93 |
£6.93 |
|
SPARK
PLUG COVER GASKET |
90354393 |
1 |
£1.66 |
£1.66 |
|
DISTRIBUTOR
TO TIMING COVER GASKET |
8930204 |
1 |
£0.08 |
£0.08 |
|
DISTRIBUTOR
INSULATOR COVER(UNDER ROTOR) |
90140538 |
1 |
£1.56 |
£1.56 |
|
CAM
COVER GASKET |
90324737 |
1 |
£18.53 |
£18.53 |
|
CAM
COVER TO HEAD SPARK PLUG HOLE RUBBER SEALS |
90324738 |
6 |
£1.50 |
£9.00 |
|
INLET
MANIFOLD / FUEL RAIL TO HEAD GASKET |
90412433 |
2 |
£8.80 |
£17.60 |
|
TIMING
COVER GASKET A |
90322538 |
1 |
£1.34 |
£1.34 |
|
TIMING
COVER GASKET B |
90322539 |
1 |
£0.61 |
£0.61 |
|
VALVE
STEM SEALS + 1 |
90215296 |
25 |
£0.99 |
£24.75 |
|
(bought extra seal cos I knew I'd scrap one which I did) |
|
|
|
|
HEAD
GASKET |
90392502 |
1 |
£56.10 |
£56.10 |
|
|
|
|
|
£202.19 |
|
|
|
|
|
|
|
|
|
|
|
|
|
OILS SEALANTS |
|
|
|
|
|
ENGINE
OIL FILTER |
93156953 |
1 |
£4.88 |
£4.88 |
|
ENGINE
OIL 15W/40W 5LTR |
91155640 |
2 |
£6.80 |
£13.60 |
|
GEARBOX
OIL 1LTR |
90540998 |
2 |
£6.38 |
£12.76 |
|
LSD
DIFF OIL 1LTR |
9293688 |
2 |
£7.06 |
£14.12 |
|
LSD
DIFF OIL ADDITIVE |
90004033 |
1 |
£2.60 |
£2.60 |
|
5
LITRE ANTI FREEZE |
91145602 |
1 |
£5.78 |
£5.78 |
|
OIL
PUMP COVER SEALANT GM SPEC 1503166 |
90542114 |
1 |
£3.70 |
£3.70 |
|
Black silicon sealant |
90485251 |
1 |
? |
? |
|
|
|
|
|
£57.44 |
|
|
|
|
|
|
|
|
|
|
|
|
|
HARDWARE |
|
|
|
|
|
CAMSHAFT
JOURNAL CAP NUTS |
11040197 |
28 |
£0.08 |
£2.24 |
|
INLET
AND EXHAUST MANIFOLD NUTS |
11082413 |
36 |
£0.22 |
£7.92 |
|
FLYWHEEL
BOLTS |
90342943 |
8 |
£0.47 |
£3.76 |
|
|
|
|
|
£13.92 |
|
|
|
|
|
|
|
GENERAL PARTS |
|
|
|
|
|
PRIMARY
TIMING CHAIN GUIDE LEFT LARGE |
90324697 |
1 |
£39.95 |
£39.95 |
|
PRIMARY
TIMING CHAIN GUIDE RIGHT SMALL |
90352572 |
1 |
£20.66 |
£20.66 |
|
CRANKSHAFT
TIMING CHAIN SPROCKET |
90323821 |
1 |
£70.13 |
£70.13 |
|
EXHAUST
CAMSHAFT SPROCKET |
90324524 |
1 |
£34.32 |
£34.32 |
|
INLET
CAMSHAFT SPROCKET |
90324525 |
1 |
£11.20 |
£11.20 |
|
CAMSHAFT
BOLTS |
90324696 |
2 |
£5.44 |
£10.88 |
|
SECONDARY
CHAIN TENSIONER COMPLETE |
90352331 |
1 |
£60.78 |
£60.78 |
|
CHAIN
TENSIONER PLUNGER |
90354743 |
1 |
£27.48 |
£27.48 |
|
OIL
PUMP GEAR SPLINED |
3448763 |
1 |
£14.20 |
£14.20 |
|
OIL
PUMP GEAR |
8930038 |
1 |
£12.62 |
£12.62 |
|
RELEIF
VALVE KIT AND PUMP COVER |
90324612 |
1 |
£39.53 |
£39.53 |
|
OIL
COOLER THERMOSTAT |
90169054 |
1 |
£11.05 |
£11.05 |
|
THERMOSTAT
'O' RING |
90067930 |
1 |
£1.68 |
£1.68 |
|
THERMOSTAT
HOUSING TO HEAD GASKET O RING |
90324889 |
1 |
£1.03 |
£1.03 |
|
WATER
PUMP |
90444170 |
1 |
£75.65 |
£75.65 |
|
WATER
PUMP GASKET |
90190983 |
1 |
£1.99 |
£1.99 |
|
SPARK
PLUGS |
90509739 |
6 |
£2.46 |
£14.76 |
|
ROTOR
ARM |
90006547 |
1 |
£4.80 |
£4.80 |
|
DISTRIBUTOR
CAP |
90369031 |
1 |
£17.51 |
£17.51 |
|
CRANKSHAFT
SPIGOT BEARING |
90105743 |
1 |
£1.72 |
£1.72 |
|
CLUTCH
KIT COMPLETE |
R1020043 |
1 |
£74.80 |
£74.80 |
|
ENGINE
BLOCK DOWEL PINS |
90343317 |
2 |
£0.21 |
£0.42 |
|
ENGINE
MOUNTING |
90079241 |
1 |
£26.14 |
£26.14 |
|
FANBELT |
91126384 |
1 |
£20.66 |
£20.66 |
|
|
|
|
|
£593.96 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
PARTS |
TOTAL |
£992.31 |
|
|
|
|
|
|
|
|
|
GRAND |
TOTAL |
£1,446.23 |
|
|
|
|
VAT |
£253.09 |
|
|
|
|
|
£1,699.32 |
|
