Project Type R - Phase 2.5

[Dave K]

Well after finally moving house and getting everything sorted I'm back spannering on the car, but for a different reason.

As most of you know it was suspected that the head gasket/gaskets had gone so the car was taken off the road last week.

The last thing I did before moving was to port the compressor housing to maximise flow;

Still need to weld the inlet on to housing though, but that should be it done.

Edited June 20, 2008 by Dave K

[Dave K]

Last weekend I removed all engine bay parts ready for the pull;

IC pipes off;

Alternator out;

Air con out;

Rad out;

Turbo out;

Gearbox split and clutch plate disengaged;

Called it a day there as was too dark to continue.

Edited June 20, 2008 by Dave K

[Dave K]

Pulled the engine yesterday morning;

Took a bit of riggling about and the gearbox jacking up but got it out;

Engine bay in need of a clean;

In the garage;

At which point I went the motor show for an hour, usual stuff but a few good cars also meet Graeme/Helen and John/Donna.

Edited June 20, 2008 by Dave K

[Dave K]

First job on return plugs out to assess condition;

No.3 had a small amout of oil on, what a surprise No3. being the problem;

Checked cambelt alignment and it was all timed ok so no teeth jumped;

Next wiring loom off;

Followed by parrallel fuel rails;

Drained the oil;

Crank pulley off;

Lightened flywheel off;

Inlet manifold off;

Water pipe off;

Cambelt and tensioner off;

Idler pulleys off;

And rocker cover off;

Edited June 20, 2008 by Dave K

[graeme_stuart]

Bl**dy hell Dave.... It looks like a car horror film. It even has all the car blood thing dripping out of the engine. []

[graeme_stuart]

Bl**dy hell Dave.... It looks like a car horror film... It even has all the car blood thing dripping out of the engine. []

[Dave K]

Lol, that was the easy bit!

Removed cam pulleys;

Removed cams and ex buckets/shims;

Some major torque in those head bolts;

Bores look good, can still see the honing and no score markings;

Fair bit of carbon build-up on pistons, from what I have found on web this is because I have been running around on low revs but with safe fuelling for a while.

Plus the car has done 75k, No3 looks to be the odd one out on the burn pattern;

Valves looking a bit grubby, discovered why there is so much oil being burned, the PCV was goosed so that is getting binned and blocked off with block venting to the catch can for rebuild;

Repeat on other bank;

Heads ready

One redundant short block;

Edited June 20, 2008 by Dave K

[John st1]

Well you have been busy over the weekend,  cant wait to see your car when it is all done.  Seeing that you seem to know alot about these cars, I am thinking of getting a dump valve and hks powerflow filter but only if  the engine will beniefit from these items. .   

[Dave K]

Hi John, dump valves get mixed opinions re benefits, if setup correctly they will help but mainly added for sound.

As for a filter, I would put a good K&N panel filter in your existing air box, works just as well and it don't mess you MAF up due to vibration that some filters cause if not mounted properly.

But to be honest if you are looking for some more go then I would concentrate more on the exhaust side.

Get rid of the cats in the system, this is where you will see the biggest gains, in power and sound. []

[Dave K]

Had a few days off after the hol so got stuck back into the engine strip.

First had to purchase a 14mm allen socket to remove the access plugs, gudgeon retaining c-clip can be seen;

Plug, c-clip and gudgeon pin removed;

All access points are 14mm allen plug except No.4 which is a plate held with two impact driven cross head screws;

Plate, c-clip, gudgeon pin and piston removed;

All removed, no signs of and major damage to the pistons;

The empty bores;

Ready for sump removal;

Oil pickup removed;

On inspecting the oil pickup I found a piece of swarf in the mesh;

All block bolts removed and ready for split;

A few taps with a rubber mallet seen the two halves split;

All main bearings look good on o/s half;

Crank sat in n/s half;

Bearings in n/s half with slight pitting to one bearing;

All the big end bearings had slight wear, which was expected;

No.1 rod;

No. 2 rod;

No. 3 rod, which had picked up and is where the swarf in the oil pickup had come from!;

No.4 rod;

One crank;

One set of rods;

Edited June 20, 2008 by Dave K

[Dave K]

How to mod a Knocklink to fit A-Pillar pod;

Kit required to do the job;

Split Knocklink case open;

Drill case and fit;

Remove led's and replace with wire of appropriate length to reach pod, also note only one earth wire is require;

Fit back in case and feed through;

Finished unit;

Led's fitted to pod with eyelets and all negative legs soldered together;

Fit to pillar and job done;

First led shows unit is powered;

Edited June 20, 2008 by Dave K

[Dave K]

Bloody forum can’t edit old posts, they fixed it at last.[]

[blue boy]

The Knocklink looks VERY good Dave..................Like It!!!!!!!![H][Y]

[blue boy]

The Knocklink looks VERY good Dave..................Like It!!!!!!!![H][Y]

[blue boy]

Ooops Sorry about that it is early!

[Criss]

Your a brave man [Y]

Good luck with putting it all back together when your done! Hope you labled up all the bolts [:S]

[Dave K]

Cheers, only time will tell, hopefully I wont have to many problems.

Moved on to sorting out all the ancillaries ready for the rebuild. Started on the power steering pump;

What a place to put the bolts, think the older style units are on the outside;

Which revealed the leaking o-ring that has been pi$$ing all over my cambelt cover for months [:@];

Started cleaning up the mounting brackets before and after;

And then got a tad carried away with the reservoir housing!;

[Cret]

Looking blingy as ever you big tart!  Very nice.

[John st1]

So when do you think that the car will be back on the road...?

[ASTiMAN]

Hi Dave

So where are you up to now? What have you decided upon and who's doing the build?

With the big power build you know you'll want a 20g and I might just happen to know of someone willing to sell!

I've started shedding weight - binned the standard seats and put Cobra kevlar bucket seats in with harnesses, smaller Momo steering wheel without airbag etc. Not sure about the Garrett GT and dogbox at the moment - getting married a week before Christmas and the bills are mounting up big time!

Regards

Andrew

[Dave K]

So when do you think that the car will be back on the road...?

Will be new year now before it's running.

[Dave K]

Hi Dave

So where are you up to now? What have you decided upon and who's doing the build?

With the big power build you know you'll want a 20g and I might just happen to know of someone willing to sell!

I've started shedding weight - binned the standard seats and put Cobra kevlar bucket seats in with harnesses, smaller Momo steering wheel without airbag etc. Not sure about the Garrett GT and dogbox at the moment - getting married a week before Christmas and the bills are mounting up big time!

Regards

Andrew

On splitting the block I discovered I'm lucky to have a rear thrust bearing block even though it should have been a middle thrust, must have one of the very last phase 1 cars using a phase 2 block and crank.

So doing the build myself![]

Is very tempting, will have to wait till after the run in on the 16g, have to use it after all the work porting it.

Mmmmmmm stripped out racer style, what you doing with the old seats? You going GT30R, twisted setup?[]

Fen tells me you have fitted new suspension as well?

Congrats to you both.

[Dave K]

Just fitted a momo myself, not for weight saving though.  Got a brand new boss and wheel on e-bay dirt-cheap.

Remove airbag retaining screws, after disconnecting the battery for a few mins;

17mm main nut;

Leave the nut on the end, so when you pull it off you don’t smack yourself in the head;

Airbag/horn wiring;

Case cracked open;

Unit removed, just need to adapt the boss to work the indicator cancel;

Boss in place;

Fitted;

[Dave K]

Found these on ebay, genuine philips Bi-Xenon HID kit circa £350! new for £41 second hand [];

Fitted and all working, so much brighter that I had a burn spot on my eyes for half hour after looking at them![:$] obviously need adjusting.

[Dave K]

Back to the build.

Acquired these for nowt;

So bought the comp to go with them;

On strip down I discovered my cam belt tensioner was leaking, lucky for me it hadn’t failed. So new tensioner purchased;

Block halves ready for full degrease and clean;

Don’t look much better but fully cleaned and all oil ways blasted dry with the new air line;

Bores have been greased to stop them rusting.