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« on: 20:29, Fri 05 October 2012 »
Had my engine rebuilt by a member on RTOC fishead
Heres what was done
Remove engine and gearbox. Strip clean and paint engine and box. fit piper 285 performance camshaft kit inc uprated valve springs, and vernier timing gear. Fit tubular exhaust manifold, hybrid turbo, lightened flywheel, uprated clutch kit, new engine wiring loom, front mount intercooler kit, oil cooler kit, performance air intake, engine breather catch tank, uprated cooling fan assembly and other supplied cosmetically enhancing products. Fitting of supplied efi related sensors ready for future efi conversion
Fit new front bumper inc modifying of all related components to incorporate large intercooler, fit and set up supplied AEM TRU Boost electronic boost controller.
Strip, clean, prep and paint engine bay front bumper and bonnet to requested ‘show’ std.
Install full cosmetically refreshed unit to highest visually appealing std testing for fit, function and security
Full on road ‘live’ set up of boost controller and carburettor fuelling requirements
removed power unit from vehicle, removed fixings ect from engine bay, degreased and chemically cleaned, prepared engine bay ready for transport to body shop.
Degreased and chemically cleaned power unit ready for work. striped engine/box of all ancillaries wiring ect and sealed units. C/o further chemical cleaning preparation for painting. Removed cylinder head, oil sump, timing cover and 5"‘ gear cover. Painted engine/box all covers brackets and all related parts in requested colours with suitable oil resistant products.
c/o cylinder head inspection, stripped engine bottom end ’n preparation for performance camshaft fitment.
Fully stripped engine down, components sent to engineer for machining. Engine block internally cleaned and prepared for rebuild inc all internal oil/water channels.
Full crank grind/polish
Full crank assembly balance inc pistons, rods flywheel and clutch
Cylinder head decoke
Cylinder head pressure test
Cylinder head repair to snapped water pump bolts
New valve seats cut
Cylinder head reface
New cylinder liners measured for protrusion, recorded and adjusted accordingly. New piston ring and piston clearances checked and adjusted as required. Liners final fitted In correct protrusion orders with new seals and clamped. Crankshaft trial fitted to block checking. adjusting bearing clearances as required. Crankshaft final fitting using suitable assembly Lube. Piston rod assembly trial fitted for bearing clearances check and adjustment. New piston ring, piston, rod assembly final fitted with assembly lube. Piper camshaft inspected and
fitted. Crankshaft and camshaft end float checked. New timing chain and tensioner fitted, cam timed to std setting. Distributor and gear fitted to correct std timing with a new seal. Cam followers checked. polished and fitted with lube. New refurb oil pump kit fitted pre filled with suitable lube.
Cylinder head fully overhauled inc lapping of valves, new stem seals refitted up with uprated valve springs, new gaskets and water pump Inlet and exhaust manifolds ?fitted with new studs lock nuts and gasket. tubular manifold requiring modification.
Cylinder bead fitted to block using new ‘uprated’ head gasket and bolts, installing checked, cleaned push rods and fitting overhauled, strip, cleaned, polished shaft, refaced tappet faces and new ‘plugs' rocker assembly.
Valve clearances and camshaft timing measured and adjusted as required.
All freshly prepared engine covers, brackets ect fitted Inc oil cooler take off plate and pipes, with new nuts, bolts and seals as required.
Carburettor stripped, cleaned, painted and fully overhauled with a new gasket kit, then fitted with a new spacer and gaskets. New engine wiring loom modified to eliminate perk fan requirements and ?fitted.
Bottom pulley with new efi timing sensor fitted to correct tinting inc new aux drive belt.
New crank seal fitted, lightened and balanced flwheel and clutch assembly fitted using new bolts.
Gear box fitted along with starter motor and freshly prepared mounts, brackets ect. Wiring loom correctly routed ensuring security and movement.
Hybrid turbo fitted with new braided oil feed and drain pipes.
Engine bay fitted up, all brackets pipes fixings cleaned, painted as necessary, all new nuts, bolts ect to ensure visual appeal. New accelerator cable kit, battery terminals and power cables fitted.
Power unit refitted to vehicle using all new nuts bolts jubilee clips ect inc new exhaust fitting kit.
Modified induction and breather systems arranged and fitted
intercooler, oil cooler and bumper modified fixings made and fitted to best possible std.
Vehicles starting charging electrical system fully repaired rewired as required.
Engines compression, oil pressure primed, checked and recorded. Cooling system filled using long life coolant mix, air bled. Engine started and run up to temp, checking for noise, leaks correct fan operation.
Tappets reset, head retorqued and oil changed.
AEM boost controller installed and set up
Vehicle road tested, then rechecked for leaks ect. Miles put onto engine as a brief run in period.
Full testing c/o setting up the boost controller, checking adjusting carburetion as required whilst monitoring for any issues/det.
Cylinder head - 73.34mm
All bearing clearances ring gaps good
Compressions, cold engine 6hrs old 150psi +- 3psiacross all 4 pots
Oil pressure, hot engine 30 psi idle - 50 psi at 4k
Boost - 1bar engine
Afr -wot 11.8 -12.1
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