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Subject:'91 Carat - maintenance report
From:John Rodgers
Date:Fri, 6 Mar 2015 16:32:33 -0600

Finally opened up both sides of the 2.1 L WBX to see what was going on.
Ultimately, four push rods were bent - all on the exhaust valves. It makes
sense. Results of an overheat incident. The heads got hot, the exhaust
valves always being the hottest even in normal operation, suffered a
tightening of the guides under the stress of overheating, and they in turn
seized upon the valve stems, there by stressing the rockers,  The rocker
arms,  being loaded by the friction induced, pushed extra hard on the
pushrods. The push rods, being squeezed extra hard by the lifters at the
botton of the valve train and the rockers at the top, had nowhere to
releive the extra forces applied on them so the weakest link in the valve
train failed by bending,  ejecting  the force sideways. The forces were so
great on one of them as to bend hard enough to strike the side of the
pushrod tube and split it, thus causing my oil leak.

New pushrods, and valve adjustments took care of it almost. One lifter will
not pump up. It gets replaced shortly.

I'm sure this episode shorted the life of the engine considerablely. But, I
will drive it in  the meantime. It seems to be running well inspite of the
over heat episode.

The oil light started flickering at idle. My hat is off to DENNIS HAYNES
for solving that one. Boosting engine speed to idle at 950 RPM solved the
problem.

Discovered the boss for the security bolt securing the alternator tension
was stripped. Required a thread insert. Worked well. That bolt is 8 mm for
those intere sted

During the inspection for the work, it was discovered the muffler and tail
pipe were in really bad shape. Both get replaced next week.

CV'S are also scheduled to be done shortly.

John