4.6 stroker engine rebuild nightmare story (Cylinder 2 at 35 psi)

Carve

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Apr 2, 2018
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130
Location
Albuquerque, NM, USA
My 2004 Rubicon was giving me low oil pressure at idle when warm, and glitter in the oil, at only 128k. I think it spun a cam bearing. It's an engine out service, and since I wanted more power, I had an (alleged) engine builder I wheel with rebuild the bottom end with a stroker kit from cleggs. He claims to have built the stroker in his Jeep and it ran STRONG. Months later, he hadn't even pulled my engine, and was putting other jobs ahead of mine (I paid him half down). I reluctantly let him take a block he had lying around to the machine shop instead of my block. A couple months later, he had it back from the machine shop, but still hadn't touched my Jeep. A few months later...no progress, so I asked to go recover my Jeep, parts and machined block.

He had actually assembled the engine, but put his used head with god knows how many miles on it instead of my head! I recovered it, took it to a shop and had it installed within a week. First start and....it misfires badly at idle. The shop took it on a brief test to ensure the new clutch was working properly. I picked it up and prayed it would run better at break in. I started and idled at 2k (it doesn't misfire that bad above 2k) until temps started to come up, and then drove around 35-40 mph city streets for about 20 miles, keeping it around 2k even at stops, and it ran slightly less crappy afterwards. Slightly. It still felt less powerful than my old engine, and idled like crap. One cylinder doesn't fire at all at idle though. I also replaced the spark plugs and coil pack, but it made no difference. I looked for vacuum leaks and verified the injectors were working.

I asked the install shop to check it out. The put a compression tester on cyl 2- the most accessible cylinder, and it was 35 PSI! The engine builder claims my break in procedure was too aggressive and I fried my rings, which is BS. Then he threatened to "beat the life out of me" if I called him out again. (This is Billy Bryan of Edgewood New Mexico. Beware! Incompetent, lazy, and homicidally dangerous)

I figured I'd do a full compression test to see what I'm looking at. Here are the results...

Cyl Dry Wet %
1) 95 121 127%
2) 35 39 111%
3) 89 100 112%
4) 97 117 121%
5) 101 127 126%
6) 94 123 131%

Interesting points: cylinders 2 and 5 are the ones the computer says are misfiring, but those have the worst and best compression. It says 5 is the worst. Maybe my scanner has them transposed. Cylinder 1 is the one at the front, right? This is a 9.3 compression ratio so I was expecting pressures over 135. The interesting thing is only a couple cylinders get anywhere near that when wet. Of course, they should all go up SOME because the oil decreases the volume of the cylinder a little, as well as the improved sealing. They're still not going up anywhere near the level I expected though

Thoughts? Cyl #2 is particularly interesting because it barely changed, which suggests a bad valve, yes? I actually did that one a 2nd time using a LOT of oil and it still only got up to 60 (no doubt because the oil was taking a significant portion of the cylinder volume). Might my head just be worn out, or do you guys think the rings are toast, too? Also...has anyone had any luck about suing a mechanic? I'm already in this for over $5k and 8 months of wasted time, and I'm worse off than when I started.

Thanks
 
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If you used a CC you can call up and dispute the charges.

Your state should have a bureau of consumer affairs and possibly an office specializing in auto repair shops/licensing. Find them and make a detailed report.

The Better Business Bureau and your local chamber of commerce are also good resources for mediating a resolution.

As to your Jeep...first thing I'd do is find a 4.0 on CL or FB or whatever for under $1000 and pull your engine and swap in a used whatever to get back to wheeling.

Then I'd tear the new engine apart. I'd video everything (and make videos for YouTube) and measure all the tolerances.

Sounds like you spun a bearing and have some bad rings. I'd still check everything.

When you're done with the new engine you can flip the spare you bought, rebuild it as a hot spare...or a combination thereof.

Also don't be afraid to buy another Jeep for the engine. Lot of times you can get ahead selling off the parts and end up with a free engine.

Good luck. I had a transmission builder completely screw me. My CC company said I didn't provide enough evidence to substantiate the disputed charges. I didn't sue because the shop is in another county and I'd already made eight four hour trips.

-Mac
 
If you used a CC you can call up and dispute the charges.

Your state should have a bureau of consumer affairs and possibly an office specializing in auto repair shops/licensing. Find them and make a detailed report.

The Better Business Bureau and your local chamber of commerce are also good resources for mediating a resolution.

As to your Jeep...first thing I'd do is find a 4.0 on CL or FB or whatever for under $1000 and pull your engine and swap in a used whatever to get back to wheeling.

Then I'd tear the new engine apart. I'd video everything (and make videos for YouTube) and measure all the tolerances.

Sounds like you spun a bearing and have some bad rings. I'd still check everything.

When you're done with the new engine you can flip the spare you bought, rebuild it as a hot spare...or a combination thereof.

Also don't be afraid to buy another Jeep for the engine. Lot of times you can get ahead selling off the parts and end up with a free engine.

Good luck. I had a transmission builder completely screw me. My CC company said I didn't provide enough evidence to substantiate the disputed charges. I didn't sue because the shop is in another county and I'd already made eight four hour trips.

-Mac

Thanks. This is a guy who just builds engines and works on Jeeps as a side gig out of his garage.

I injured my back and working on the Jeep for anything much more than swapping out easily accessible parts can have me hunched over in severe pain for days, plus my garage is less than ideal for engine hoists and stuff, so I'll have a shop do it. That's like $1700, so I don't think I'll go with a temporary engine.
 
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Here's the inside of #2...the one only going to 35 psi. Looks like some scoring....but enough to only build 35 psi?

IMG_5317.JPG


IMG_5319.JPG
 
What do you think about that score line though? Maybe it has a broken ring?
or he didn't index the rings properly.

Too bad you pulled the head without doing a leakdown test. Now you're just guessing where the problems are until further teardown and repair. I'd be tempted to get a valve job,then slap it back on and do leakdown and compression rather than pull apart the bottom end.
 
What do you think about that score line though? Maybe it has a broken ring?

Possibly a broken ring, you need to investigate that as well. First I’d turn the head upside down and fill the valve area with water. Blow compressed air into the intake and exhaust ports. See if there are bubbles indicating a leaking valve. If you have a chipped or burnt valve the water will run out the ports. Simple trick for checking heads.
 
or he didn't index the rings properly.

Too bad you pulled the head without doing a leakdown test. Now you're just guessing where the problems are until further teardown and repair. I'd be tempted to get a valve job,then slap it back on and do leakdown and compression rather than pull apart the bottom end.

I've not pulled anything but spark plugs. Those pics are from a $25 Amazon special borescope
 
What did the plugs look like? What are the balls on the piston?

The spark plugs are new and look fine. The gunk on piston #2 might be due to it not firing at idle

For comparison, here's #5. This one is also reporting a misfire, but has the highest compression. Those vertical lines look concerning
IMG_5305.JPG