Engine rebuild and power mods

[Davey Boy]

Woo Hoo...go Pete!:thumb2

 

[luke1987]

Looking at your pics Pete it looks spot on, Its advanced the timing which would make sense from the way the cam has been re-profiled. Make sure you get a start up video nothing like that tingly bol***k feeling when it first runs.

 

[makeitfit]

Looking at your pics Pete it looks spot on, Its advanced the timing which would make sense from the way the cam has been re-profiled. Make sure you get a start up video nothing like that tingly bol***k feeling when it first runs.

Man I'm glad you said that
I've read too much, done the job too many times and still wasn't sure. I thought I'd got it but you know , just a little erm, is it ? :augie:lol
According to various reads, I understand that each 4 degrees of advance will bring power band down 200 rpm. Is this something you're aware of ?
There will be video for sure. We're also trying our arm to get on the local college rolling road . We need a day on it really to experiment with fuel pump timing

 

[makeitfit]

Assembly time , again.

It's got cold outside so brought the Black Pearl in for a warm

I had the zorst mani machined flat again as I just couldn't get a good seal last time I put it together :doh
Nice new quality gaskets too.
Pre-assembling as much as I can lift before refitting the head.

I hope this the last I see of these pistons for a while :bow

Head on and torqued

Next step + 90 degree power crank on the long bar :thumbs

Then all that fiddly turbo install and associated pipe work.
Rocker assy and valve clearances all done.

Hope to have some pump fiddling tomorrow then fingers crossed some key turning
Onwards

 

[Banshee]

Pete you are my spirit!!!!!!! :splif

When I see you grafting it really kicks me up the arse :thumbs

I hear we are due some snow from Siberia in the next few days as I was walking around the factory at work earlier :nenau

 

[makeitfit]

When I see you grafting it really kicks me up the arse :thumbs

Bend over sunny Jim, I've been busy again
So another day of delivery chaos and so I decided to sod 'em and go to the unit :augie
I did stuff to the pump
Here's the Zexel mechanical pump readily accessible before the power steering pump goes back on.

Top off reveals what I'd hoped, a version of the bosch VE pump.


Euw, looks a bit scabby in there
Anyway at least it has a star wheel and fuel pin that I can turn a bit.

The theory is to turn the star wheel down to the bottom, thus reducing the preload on the diaphragm via the spring. After a jolly good clean that's what I did.
Then the fuel pin is rotated to get the most acute shape against the governor follower. Also binned the nylon bush so the fuel pin can move even further.



All clean and reassembled. The diaphragm is already sitting lower.
I've marked it as a ref incase I got it wrong.

Working too fast , doh :lol

Ready for some life giving fluids at last :clap

I wonder what will happen next :naughty
Onwards

 

[makeitfit]

Extra added bonus
Here's the actual genuine first turn of the key
https://youtu.be/Ca7u4btuvwg

 

[solarman216]

Sounds nice Pete, get that inter cooler on and lets hear some revs, Rick

 

[makeitfit]

Later on with all the fluids checked and so on, I was happy to go for a test drive.
Needless to say I'm bloody chuffed to bits.
It pulls really nicely, boost comes in earlier and already at 1.4 bar.
No over heating, EGT stayed below 500 even on a long hill drag. Early hours but it seems ok.
Got some tweaking to do now as it runs in .

<iframe width="560" height="315" src="https://www.youtube.com/embed/4KcrmWxqrDk" frameborder="0" allow="accelerometer; autoplay; encrypted-media; gyroscope; picture-in-picture" allowfullscreen></iframe>

 

[solarman216]

The pump unit should have 5ml oil in it, only discovered this with a full explanation of the moving parts via a download, Rick

 

[makeitfit]

The pump unit should have 5ml oil in it, only discovered this with a full explanation of the moving parts via a download, Rick

Ah rats, I did loob it but not 5mil of oil. Does it say what kind of oil ?
I'll be visiting the pump again soon to fit a new fuel pin. I've seen some more aggressive shapes on the market so I'll oil it then :thumbs

 

[Davey Boy]

Just brilliant Pete!:thumb2

 

[solarman216]

Ah rats, I did loob it but not 5mil of oil. Does it say what kind of oil ?
I'll be visiting the pump again soon to fit a new fuel pin. I've seen some more aggressive shapes on the market so I'll oil it then :thumbs

No I used engine oil, be interesting to see how you get on with the adjustments, I am still chucking out a fair bit of smoke when I floor it, but like the feel of power and it went through the MOT as is :naughty, Rick

 

[luke1987]

Good going Pete I knew it would work out wish you were closer would loved to have helped. Im dying to cut my centre box out now just for that sound.

 

[makeitfit]

Good going Pete I knew it would work out wish you were closer would loved to have helped. Im dying to cut my centre box out now just for that sound.

You've helped lots anyway mate.
You wait till you here it angry :naughty
How are you on VE type pump mods ?
I've dropped the star wheel to the deck but I've read from other sources I may lean out at high throttle/boost positions :augie
So I'm thinking now of having the LPG switched to come in at say 1 bar
That should be fun :naughty

 

[makeitfit]

A hundred mile engine check today. All seems well apart from a bloody annoying oil leak from the rocker cover. Now tweaked.
New glow plugs in as one or two not playing ball.
Intercooler pipes now have mikalor clamps all round . Jubilee clips just don't cut it .
Keeping the gas off for the mo till we've done a few more miles.
Fingers crossed for a new year gas test :naughty




Also fitted a new oil catch can . Simply vented to atmosphere at mo


The oil return pipe from the old crankcase vent is now vented to high level with all the diff breathers too.