Time for engine rebuild (1972 m10 2.0L )

Hardware

This is the second time i need the nuts and bolts list for a full engine rebuild so i've decided to make a list once and for cause wallothnesch.com (sometimes, when not discounted) charges 94 EUR and even when discounted to 63.82EUR, with shipping and taxes (for me) it might get to almost 120EUR (475 NIS). 

Nuts and bolts set for engine 1502,1602,1802,2002 carburetor models 265 pcs all yellow zinc plated

So i made a hopefully complete list of hardware, available on Google Drive
https://docs.google.com/spreadsheets/d/1PomjZJDtcmhznTM8tIMvMIN3G81YLPwwaeeuKzYfExA/edit#gid=0 

Engine housing mounting parts
7119913483	M6X25	4	wave washer	B6	4
7119901125	M8X25	2	wave washer	B8	2
Wheel casing
7119913676	M8X35	3	wave washer	B8	3
7119901189	M6X35	9	wave washer	B6-ZNS3	12
7119912310	M6X40	1
7119913483	M6X25	2
Oil Pan
7119904524	M6X16-U1-8.8	21	Hex bolt with washer
Engine Suspension
7119919969	M8X20-8.8 ZN	1	Fillister-head screw
7119904033	M10X18-8.8-ZNS3	5
7119932122	B10	7	Wave Washer
7119932095	B8	7
7119904032	M8-8-ZNS3	4
7119903039	M8X20-ZNNIV SI	1
7119915558	M10-8-ZNS	2
7119913662	M8X30-ZN	1
7119904533	M8X50	1
7119912800	M8X70	1
Cylinder head/cylinder head cover
7119932072	B6	7
7119904116	M6X30-8.8-ZNS3	1
11121720113	M6-Z1	6	Cap nut
7119932072	B6	7	Wave washer
Crankshaft/flywheel
11220616143	M12X1,5X22	8
7119921656	M20X1,5	1
Camshaft
7119904357	M6X16-8.8-ZNS3	6
Dipstick
7119904357	M6X16-8.8-ZNS3	4
Oil filter
7119913652	M8X22	1
7119904533	M8X50	2
7119912800	M8X70	1
Water pump
23317545769	M6X18	4	(fan)
7119913021	M6X28-ZNS	3	(water pump)
7119912567	M8X90	3	(water pump)
7119913021	M6X28-ZNS	3	(water pump)
7119963034	A6,5X9,5-CU	4	(gasket ring)
Intake manifold
7119932095	B8	8	Wave washer
11611713432	M8	8	Hex nut wiht flange
Exhaust manifold
11621744323	M8 SW12	8	Hex nut

this list should be shared on carzbook.com

Oil pump

Until now i've opened 3 oil pumps and signs of wear were visible on all of them which makes sense after 40 years but i was never aware that there's an Intermediate plate (11411263218) which spares the casing ... the cheapest place i found is partacus.de  for 5 EUR.

Cylinder head is beyond reliable repair :(

Turned out that the 2002 121 cylinder head had too many faults and one was a crack that compromised the entire idea of safely using it :(


So I've started to look for alternatives cause i really don't want to put it all together and then do it again.

It took me many years to get to the maturity level on which i can wait and plan as opposed to just do something half way and regret the final outcomes.















Amazingly enough i've found a brand new e21 1.8 head at a "reasonable" price:

Internals are interchangeable only the valves are bigger. 

1972 2002 M10 Engine with 4 speed manual sourced.

M10 2002 engine with 4 speed manual gear and small Solex carb.

I had a very rare opportunity (only 100 of the 02 series were sold here)  to buy a 2002 engine for my 1802 from the same guy that sold me both 1802 cars (1974, 1975, Chamonix and Amazongrun).

It was sitting in his yard and of course untouched for years. It came off from a working car with the front bridge and lacked some accessories that maybe he sold during the years.

Not being aware of the great exchangeability of the E10/M10 with the later platforms,  i considered that this is my only chance to convert my 3 speed automatic 1802 to a real manual (4 speed) 2002.

So the saga began...

We cleaned it and took it apart hoping for the best which turned out to be much less than best but better than worst.

m10 engine block cleaning

I am so sorry i missed the part when all the dirt was coming out.

Engine and gear removal

So we took down the engine, gear and front bridge, after removal the front bridge goes back to the car so it can be moved around on the wheels.

Engine condition

The previous owner said the engine head was remade and then it had some problem and it was never fixed since. That was some 15 years ago...

Looks dirty but complete beside the radiator cap which should be replaced with an aluminum one anyway  :

Now lets go further and find out what was the problem that stopped it for so many years



Some clogged "arteries" but that's probably because of the long time the cooling fluid sat in the system:

 

Ok, engine and gear goes out...

Another look



Everything looks fine up here but as it turns out after head removal, one exhaust valve had a broken lip. beside that we measured the bearings and found out the this engine was overalled in the past, meaning it's 0.25 ands we go now 0.5 away from standard.

The tail light issue resolved

So few days ago the rare tail lights arrived, found them on eBay at a reasonable price (compared to other crazy listings)

After a long wait and hope ...it finally happened

This is almost classic barn find beside the fact it was in deep hibernation " for who knows how many years in a home garage and not a real barn.

Finally after more than 6 months of negotiations and waiting,  a final tense meeting in which for long minutes i thought it will not happen and that i'll have to give up... it did :) 



The seller was so pissed off that he sold the cars, that didn't want to look for the missing tail light ...  he just wanted us to go away immediately.


Claudio helped to make this happen :)



Here the white one (Chamonix) is on it's way to Promotors (Garage) .