[engine_work] 1.6 Engine Removal, Build And Refit

[frodo_monkey 0]

Evening all!

 

I finally got my rejuvenated engine bits back from the machine shop today, so I thought I'd start a topic detailing all the fun and games I have sorting my car for next season! I've never done anything trickier than a head gasket change on the car before, so this should help out any other newbie types. I've been plotting a new engine for my race car for a while, as it felt a little tired - due to class regs I'm staying with a 1.6, but the plan is for an XU10 head, new cam and bike carbs to give it a little more oomph

 

Car as it was:

 

http://i13.photobucket.com/albums/a282/fro...nkey/frodo3.jpg

 

It is now sat in my garage waiting for me to pull the lump out (pics to follow). Unfortunately I have to build a garden shed first though as thats blocking the car in!

 

XU10J2 cylinder head as received - ported, polished, 279 CatCam, vernier pulley and 3-angle valve seats

 

http://i13.photobucket.com/albums/a282/fro...ey/PC150002.jpg

 

Block all cleaned-up with new liners (old ones had a big ridge at the top). Crank, flywheel and clutch cover cleaned up and balanced.

 

http://i13.photobucket.com/albums/a282/fro...ey/PC150007.jpg

 

Box of gubbins including my balanced pistons and rods

 

http://i13.photobucket.com/albums/a282/fro...ey/PC150005.jpg

 

I had a spare hour or two tonight, so I thought I'd make a start by painting the block and head (Hammerite Blue, I know its a red car but I like the combo). Looks better already! Hope to get this finished Sunday.

 

http://i13.photobucket.com/albums/a282/fro...ey/PC150009.jpg

http://i13.photobucket.com/albums/a282/fro...ey/PC150010.jpg

 

So thats where I've got up to so far... Lessons learnt - 1) Only ever paint engine parts on your dining room table when your missus is away!

 

Next instalment on Sunday hopefully, when I plan to have the sodding garden shed up, made a start on taking the existing engine out and finished painting

 

Also, if anyone near Northallerton needs any engine work doing I can recommend CAS Engineering who are just around the corner from Motoscope. Craig the gaffer is a top bloke and his work looks very nice

 

 

edit by cybernck: pics over allowed filesize limit!

[Guest ashnicholls]

Ha almost identical build to what I did,

 

complete novice my self.

 

Looks good, I used hamerite on the block, and seems to be ok, but do not know if it will last on the head as it gets hotter. Is it high temperature hamerite?

 

Just wish I could have afforded new liners and pistons.

 

You are using the XU6/9 head gasket aren't you?

 

Ash

[frodo_monkey 0]

Yep, a Payen XU5/9 one. I'm just using bog-standard Hammerite, but I figure it'll be fine for my purposes (racing rather than showing )

 

I've got new liners but am reusing the pistons which were fine - just re-ringed.

 

Working a 24hr shift today so no progress till tomorrow...

[max0 5]

looking good si! where did you get your engine work done? Thought you went to amac, which is very good and also in northallerton.

 

If you need a second set of hands just give us a shout.

 

Andy

[frodo_monkey 0]

I used CAS who are on the industrial estate opposite Motoscope - highly recommend them! I'll probably take you up on that when it comes to removing/reinstalling the lumps, thanks Andy

[max0 5]

I used CAS who are on the industrial estate opposite Motoscope - highly recommend them! I'll probably take you up on that when it comes to removing/reinstalling the lumps, thanks Andy

 

will have to check them out. amac comes very recommend from a lot of local lads http://www.amacengineering.co.uk/EngineMods/EngineMods.htm

[Guest ashnicholls]

Thats a very nice and informative website.

[frodo_monkey 0]

Sunday update -

 

Garden shed now done, very glad to have a garage back! Unfortunately light and enthusiasm ran out before I could do anything to the engine still sitting in the car. Therefore, I came back inside and finished painting the head and block...

 

Having now painted them both, I've just been on to GSF to get head bolts, crank oil seals and gaskets various - another £60 gone but very competitive prices so reasonably happy.

 

Next tasks:

 

- Take the head down to either Boggs or Shenpar for them to make an inlet manifold suitable for bike carbs. Thinking I may go to Shenpar later this week as they're willing to swap the R6s for R1s (only really got the R6s 'cos I found a cheap set).

 

- Clean up and degrease the crank, liners & pistons, then get the block assembly onto the engine stand.

 

- Drain the fluids out of the engine in the car, and remove most of the front end including the radiator.

 

- Paint the garage...

 

Its all go really!

 

Frodo

Edited December 17, 2006 by frodo_monkey

[Atari Boy 11]

I am a new to this and have just started to overhaul my 1.6 engine. Is it me or does the Haynes manual makes things more complicated most of the time?

[Guest BrainFluid]

Thats right but they have to be as anal as possible about it all, best to follow what it says first time around with jobs tho' before you start making shortcuts...

[Atari Boy 11]

I suppose thats true.

Do you know of any good 205 specialists in Suffolk?

[Lucky Gti 0]

I suppose thats true.

Do you know of any good 205 specialists in Suffolk?

 

No, but if you find one let me know!!! There is a french car garage in Ipswich, which is supposed to be pretty good but only on the standard type stuff!

[frodo_monkey 0]

OK, this weeks update - progress slow due to spending all the hours in the world at work! Managed to escape early on Tues so drove down to see the Shenpar boys about my inlet manifold - great bunch of guys, very helpful.

 

They swapped my R6 carbs for R1s (for info, I can't see any way in which you can put the R6s on a 205 - the carbs are just too close together and there isn't enough room in the engine bay to sort it out).

 

Hopefully mid-Jan I'll have an inlet manifold, some refurbed carbs and all the fittings to go with them!

 

Meanwhile progress at home has been static, however I should have the shed done and garage painted by this weekend so I can crack on over the holidays with the car

 

Si

[Atari Boy 11]

Lucky Gti

 

Do you know what the place is called in Ipswich?

[frodo_monkey 0]

Have just spent an hour cleaning the block with white spirit and a rag ready to start assembling it. A quick question though...

 

I have a Clarke engine stand thing to make it a bit easier to refit crank, oil pump, fly etc and want to know how you'd go about mounting the block on it?

 

The four mounts on the flywheel side of the block at the edge look about right - is this OK, and what bolts should I use i.e. size, thread, and from any particular car (like the Ford bolt on beams thing).

 

Don't want the sodding thing dropping on my feet!

[PumaRacing 1]

Old Ford CVH cylinder head bolts are the handiest thing in the world for mounting engines onto stands with. They are long, have plenty of thread and the 10mm thread suits most continental engines. You can cut them down for holes with threads in or use them as-is with a nut for through holes. I can send you some if you can't get any from your local engine reconditioner. 10mm nuts are a few pence each from a bolt stockist.

 

It's also handy to have lots of old CVH head bolt washers for spacing things out with. Again I have a bunch of them somewhere.

 

There's lots on info on my website about bolt torque, valve clearances etc which I suggest you follow. Don't forget the correct spacers and punch a bolt into the waterpump housing.

[frodo_monkey 0]

Thanks very much Dave, I'll try locally and give you a shout if I fail dismally!

 

I've read your website quite a lot - a very informative read and thanks for taking the time to explain 'why' to us lesser mortals

 

Si (trying to be a Customer 3 )

[PumaRacing 1]

I'm glad you found the website informative. I know from feedback it's helped many hundreds of people of people over the years. You might want to ask the moderators why one of them went into my account last week, deleted my sig and replaced it with the words "link to a commercial website removed". They didn't have the courtesy to message me to say they'd done it though.

 

Seeing as I haven't been taking on work online for a year, don't tout for work on here and am about the only pro engine builder to take the time on here to answer people's queries why did they do something so petty and childish? Maybe they just don't want you to have access to one of the most informative technical engine websites in the world.

 

If anyone wants to add a link to my website to their own sig then feel free. Hopefully it will help newcomers to the forum despite the moderator's actions.

Edited December 22, 2006 by PumaRacing

[max0 5]

I'm glad you found the website informative. I know from feedback it's helped many hundreds of people of people over the years. You might want to ask the moderators why one of them went into my account last week, deleted my sig and replaced it with the words "link to a commercial website removed". They didn't have the courtesy to message me to say they'd done it though.

 

Seeing as I haven't been taking on work online for a year, don't tout for work on here and am about the only pro engine builder to take the time on here to answer people's queries why did they do something so petty and childish? Maybe they just don't want you to have access to one of the most informative technical engine websites in the world.

 

If anyone wants to add a link to my website to their own sig then feel free. Hopefully it will help newcomers to the forum despite the moderator's actions.

 

Hi Dave, a friends signature got removed for the same reason, so I wouldnt take it personal.

 

However we noticed some signatures still contain commercial sites.

[cybernck 400 1 Cars]

Dave, it's a standard procedure really and whilst your input is appreciated and

you don't directly post much about the services you offer (which isn't allowed

anyway), it's not like you don't promote yourself simply with your presence

(and some people possibly used your services because of that).

 

as for why you haven't been contacted, you've had "no PM's, email me" in your

sig for "ages" and on all the previous occasions i tried to contact you i just got

"inbox full" messages back so i didn't even bother trying to contact you this time.

 

as for obstructing access to technical information - to remind you - i really wanted

to share your technical information and i did ask you to submit/donate your pug

related articles to our website to form an "engine tuning guide" on our website

(fully credited and with a banner link to your website) but you came up with

"frequent updates" as a reason to turn the offer down, which wasn't the action

i had expected really. i then told you i would solve the problem by making it feed

the text directly from your website but you replied saying you don't want your text

on any other websites than yours. so, in a way, i could say it's you obstructing

access to your own technical information.

 

also, you feel it's right and normal to put up a link to your website on here, for the

benefit of our members. well i don't see you linking back to us on your website and

i'm sure your pug-minded visitors would benefit from finding out about our website

and forum in the same way our visitors benefit from your website. isn't that right?

 

btw, other people can't have a link to your website in their sigs either and the link

is still there in your website field in your profile, so you can always say in posts

"check my website for more information - link in my profile".

 

but since your case is borderline afterall, we're discussing it in admin.

 

 

max0> please PM me with more info and i will act accordingly.

 

 

thanks.

[Guest BrainFluid]

Aw heck I and many others do hope this turns out well in the end!

 

Maybe this is an excellent time to brush off some cobwebs and clear the air a little. Both this site and Puma's site have helped so many people between them for FREE it would be a real shame if we all stopped getting along.

 

Hope we can find a solution that suits everyone here.

 

Merry christmas people.

 

Nathan X

[frodo_monkey 0]

Right, Xmas has been and gone and, as usual, progress has been slooooooow... But I now have a shed, a painted garage and a happy girlfriend as we managed a week of seeing relatives.

 

On to the 205 - no progress at all with taking the engine out of the car, but now with the garage finished I plan on having it jacked-up with fluids removed by the weekend. The new block is sitting on the dining-room table waiting for me to check the bearing clearances. And, I've found some suitable bolts to attach it to the engine stand to - should get around to that tomorrow or Weds hopefully.

 

Struggled locally to find quite a few bits - local factors didn't know what Plastigage was - so have ordered these over t'internet:

 

Dial gauge

Degree Wheel

Plastigage

 

As soon as these come, I'll check the bearings with the Plastigage then fit the pistons & rods and the crank into the block (pics to follow)!

 

Thanks for everyones help so far - next question... Dave mentioned about punching a bolt into the waterpump housing? I've read his site but can't find a reference, does anyone know what this would do and how you would do it etc?

[frodo_monkey 0]

Picture time:

 

Garage is finally painted and dry, therefore I put the 205 back in hibernation:

http://i13.photobucket.com/albums/a282/fro...0005resized.jpg

Looks pretty happy in its new home! Also took a pic of the existing lump:

http://i13.photobucket.com/albums/a282/fro...ey/P1020006.jpg

As I left it tonight, sat on axle stands waiting for me to drain fluids:

http://i13.photobucket.com/albums/a282/fro...ey/P1020007.jpg

Thought I'd better wheel the engine stand into the dining room and 'mount it'...:

http://i13.photobucket.com/albums/a282/fro...ey/P1020008.jpg

The assembly area (or 'dining room table' as the missus would have it):

http://i13.photobucket.com/albums/a282/fro...ey/P1020009.jpg

I can recommend having an understanding girlfriend if you do the same as me

 

Next task is to check the clearances once the Plastigage gets here. After that, I'll be fitting the crank to the block, then dropping the pistons and rods in. Meanwhile, out in the garage, I'll be draining the oil and water from the 205! Pics to follow in due course.

 

Rgds all,

 

Frodo

 

edit; pugtorque; image file sizes, less than 120k please Si.

[pug_ham 240 3 Cars]

Si, is that the same garage as where we re-fitted your beam? Looks a bit different now & in daylight. Didn't think yours was a lean to.

 

Good luck & have fun with the plastigage.

 

Graham.

[pug309twin40s 1]

Thanks for everyones help so far - next question... Dave mentioned about punching a bolt into the waterpump housing? I've read his site but can't find a reference, does anyone know what this would do and how you would do it etc?

 

thats referinng to the headbolt that goes above the waterpump end. It has an extra headbolt spacer on it to stop the headbolt going through into the waterpump area. If you dont use the extra spacer on the bolt you will punch a hole into the waterpump area and ruinin the block.