Engine rebuild and power mods

[luke1987]

Me and my big mouth

 

[makeitfit]

Me and my big mouth

Yerp, I even looked it up and that http://johnmaherracing.com/tech-talk/3-angle-valve-job/
So having persuaded Mr Rally tuner dude to trim my valves and seats,I got this back

There you go, 3, count them 3 angles of shmoooth


Yes, yes, probably way over the top, but once you're in this deep what's the point of not doing it
8 little soldiers all polished up and ready for action

Now I couldn't do all this valve work and leave lumps in the port, so I decided it was time to smooth these out too :sly

Ah that's better, Mr Dremmel to the rescue . Also loads of port cleaning and crap shifting later things are looking good.

Now with the head the other way up at last I cleaned up the injector seats and glow plug holes.

Valve oil seals going on . I used an 11mm socket which seemed the best drift I could find. Oil and hammer on.

Spring compressor time again. Fiddly collet fitting. I used a gloopy oil and let capillary action do the holding on thing

Boom one valve train head assembly done. Didn't take long at all :lol

Enough for tonight. Next job followers, and rockers. Then a bit of HG action :clap
Onwards.

 

[luke1987]

Getting good at this engine building mate cant wait to see the finished item. Out of curiosity how are you controlling the boost? By the actuator or having an actual boost controller.

 

[makeitfit]

Getting good at this engine building mate cant wait to see the finished item. Out of curiosity how are you controlling the boost? By the actuator or having an anctual boost controller.

I was planning to keep the actuator but use a bleed valve . I've got an electronic controller in the garage somewhere but would rather keep it simple.

 

[luke1987]

If you use a bleed valve make sure its the ball and spring type otherwise you end up with ridiculous boost spikes and melted pistons. I had a hks electronic one I was going to fit to mine but sold it when I couldnt find a manual pump I did have a naughty thought of finding an aftermarket management system capable of running the bosch electronic pump, Now that would be interesting but I have the 205 if I want to scare myself half to death .

 

[makeitfit]

Yep ball and spring type :thumbs
I'm possibly using an Iveco 2.8 pump. It's a bit bigger plunger at 11mm and Isuzu 3.1 injectors.
Just been chatting to Timbo on faceache :thumbs
He got his old 2.7 to 200bhp with stand alone ECU

 

[solarman216]

Re valve seats is this not what I said many posts ago, Rick

 

[makeitfit]

Re valve seats is this not what I said many posts ago, Rick

I don't know was it ? Never doubt you Rick ☺

 

[makeitfit]

Late one at work today but hey still managed a bit of nut action :thumb2
Back to the engine block and cleaned up cam followers. Oiled and put back in the holes they came out of .

First anomaly of the evening was this here head gasket. That defo says "UP" but it's on the bottom :lol Is someone in the gasket factory pulling my plonker:nenau

Anyway, I'm pretty confident it can only go on one way

Head bolts cleaned , oiled and torqued. Then I'm told to paint the exhaust side and turn the bolts another 90 degrees.

Did that, but why only the zorst side :nenau

Push rods also cleaned and oiled

Finally for tonight I just cleaned up and fitted the rocker gear. Not adjusted yet. I wanted to check the manual on the head bolts .

Soon be pump time :naughty

 

[Davey Boy]

Oh looking really good Pete.
Great thread, great pics to.:thumb2

 

[solarman216]

Only doing the exhaust side 90 degrees cannot be right, but not got time to look at the manual this morning, late already, Rick

 

[makeitfit]

Only doing the exhaust side 90 degrees cannot be right, but not got time to look at the manual this morning, late already, Rick

That's what I thought but it's written quite clearly :nenau
Can't work out how to do a screen shot off the lappy lol but this is the info I have . EM page 115

 

[solarman216]

Nah typographical errors or such like, do the other bolts the same FFS common sense rules OK, Rick

 

[makeitfit]

Nah typographical errors or such like, do the other bolts the same FFS common sense rules OK, Rick

Agreed. Not that I've done many heads but it seemed really odd to have different settings on each side:nenau
Cheers Rick, I'll crank the inlet side in the morning :thumbs

 

[Davey Boy]

Quarter of a turn....Mmmm:nenau

 

[luke1987]

Autodata says do them all 90 degrees. Personally id do them 42nm 57nm and 90 degrees, You'll be good at that .

 

[solarman216]

Agreed. Not that I've done many heads but it seemed really odd to have different settings on each side:nenau
Cheers Rick, I'll crank the inlet side in the morning :thumbs

The only time I have come across unequal settings is where the head curves out to encompass the push rods and this part of the head does not form part of the water ways, oil ways or cylinder sealing, the bolts have usually been a smaller diameter as well, on all others they are torqued the same, Rick

 

[makeitfit]

Today has been a bit scrappy. Meetings, family and stuff gets in the way now and again :lol
Anyhooo, this morning I went to correct my head bolt conundrum.
90 degrees all of them . done :thumbs
Tappet clearances done but cold, so that needs doing again at some point.

Then it was back to General "Re-assembly" and Captain "Part-wash"
Glow plugs looked reasonable so in they went

Exhaust manifold , thermostat housing and so on back to base. First lost bolt tonight too I've lost the uber long one that goes down through the thermostat housing into the waterpump housing bit :nenau

Even the rocker cover was being a tit tonight. I find it really hard not to over tighten small torque numbers. Eventually all sequenced and done.

Should get time to clean up Mr Turbo tomorrow and then it's just the ruddy PUMP

 

[makeitfit]

Sunny day meant more outside kinda things to do like bees and garden .
However got a few hours this evening.
My modded Turbo is now on and plumbed :thumbs

Gloves to keep any stray bits getting where they shouldn't.

Heat shields on, alternator and belt on. Oil filter and everything else this side done

Just a pump to do now and then some brum brum may happen :naughty

Onwards

 

[Banshee]

Awesome Pete :thumb2