 | Home > Td5 > So I have the engine out and the head off |
 
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| Welkman Member Since: 02 Nov 2014 Location: Essex colchester Posts: 332  
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Ok I got carried away and am fully stripping the engine to do the bottom end bearings whilst im there. I want to paint the block and generally tidy up a few bits and pieces as its going to be a keeper
 Will take lots of photos. |
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19th Apr 2015 7:14pm |
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| Anderzander Member Since: 08 Feb 2011 Location: Lancashire Posts: 1000
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Take lots of pictures for us please !
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19th Apr 2015 7:20pm |
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| Welkman Member Since: 02 Nov 2014 Location: Essex colchester Posts: 332
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bad photo from my phone of where i am at.
 Click image to enlarge[/img] |
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19th Apr 2015 7:48pm |
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| Welkman Member Since: 02 Nov 2014 Location: Essex colchester Posts: 332
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Totally stripped now, photos up soon. There was a piece of card in the oil pan blocking the pick up from an oil filter box. Really glad I have had it apart now. Just trying to decide whether to drop it at the machine shop or clean and hone it at home??? Bearings, pistons and journals look good but will obviously require measurement to be sure.
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25th Apr 2015 4:42pm |
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| Fatboy Slim Member Since: 04 Feb 2008 Location: Bridgend Posts: 1006 
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I'd have the bores honed in a machine shop personally. They'll achieve a far better finish on a machine than by hand , not worth the aggro of ripping it to shreds again because the rings won't bed and its using 5L of oil a week.....
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25th Apr 2015 5:00pm |
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| munch90 Member Since: 26 Oct 2013 Location: guildford Posts: 3558 
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few things to think about
might be worth getting bores measured propely at machine shop if your gonna home hone then guessing your going to use one of the 3-4 stone spring loaded "honer" , there not really a honer they a graze buster and will follow any oval wear in the bore , a proper honer like a delapena will make bore round again , but you might find you have take to much out to get rid of the oval wear (thrust side of bore will wear more ) the old rings will have worn to the bore if you fit new rings to worn bore there is a good chance of bit lower compression and oil burning my advise would be get it measured by proper bore micrometer at machine shop and let them decide best course of action , also get the ring grooves checker in the pistons at same time , worn grooves can act like a oil pump moving oil up the piston to top as the piston goes up and down if bores are good and will take a hone and ring grooves good then that could be the way to go I would personally only ever rebore and new pistons BUT of course its much more expensive sorry if telling you what you already know |
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25th Apr 2015 5:31pm |
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| Welkman Member Since: 02 Nov 2014 Location: Essex colchester Posts: 332
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Hi, Thanks for the advice. I am going to take the block to the machine shop and get them to check my measurements on the bore, hone and clean. I hope I do not need to go down the new block route! Hoping to have it back together next weekend.
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26th Apr 2015 3:59pm |
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| munch90 Member Since: 26 Oct 2013 Location: guildford Posts: 3558
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Think you can get +20 pistons , so shouldnt need new block
or lined back to std Last edited by munch90 on 26th Apr 2015 4:33pm. Edited 1 time in total |
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26th Apr 2015 4:32pm |
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| Fatboy Slim Member Since: 04 Feb 2008 Location: Bridgend Posts: 1006
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I'd seriously doubt you'll need a new block. Worst case senario fit sleeve liners to any bad cylinders. Turners sell them from memory
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26th Apr 2015 4:33pm |
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| Welkman Member Since: 02 Nov 2014 Location: Essex colchester Posts: 332
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Progress:
Click image to enlarge Notice the random piece of oil filter packaging blocking the oil pick up. It could only have got in there when new or when a lower end service was happening. Click image to enlarge Crank bolt tool Click image to enlarge mucky sump Click image to enlarge Bagging and labelling everything should pay off later down the line. Click image to enlarge Click image to enlarge Block and pistons are in the wifes car now ready to go to the machine shop tomorrow for cleaning, measuring and honing. |
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26th Apr 2015 8:53pm |
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| Anderzander Member Since: 08 Feb 2011 Location: Lancashire Posts: 1000
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Brilliant ! And brilliant pics - thank you !
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26th Apr 2015 9:20pm |
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| Welkman Member Since: 02 Nov 2014 Location: Essex colchester Posts: 332
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Block ready to go; all measured up at the machine shop and the bores are fine and have been deglazed ready for the new rings. Steam cleaner hired to clean up the engine bay which I will also touch up and dinitrol whilst access is good. Looking forward to starting the rebuild tomorrow evening. Three days should see a lot of progress.
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30th Apr 2015 4:54pm |
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| Welkman Member Since: 02 Nov 2014 Location: Essex colchester Posts: 332
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Update:
The block after stripping to bare metal, painting with POR15 and POR black engine enamel x2 coats. Click image to enlarge I then made sure the deck was prepped by sanding for a couple of hours with 400 - 600 grit with a flat block. After this was a degrease, pressure wash, oil gallery clean with specialised brushed, air blast, more washing, then more washing, air gun to dry and into a clean and organised workshop for building up. Click image to enlarge I forgot to mention the sheer amount of measuring needed; micrometer and bore gauges to check bores (all in spec), micrometer on the main and big end journals (good) and then dry fitted the mains with plastigauge to check the oil clearances (again all fine) Click image to enlarge Giving these bits a good clean but no need to get them shiny as they are going to get muddy soon 
Click image to enlarge Stripped down each piston as they were cleaned by the machine shop which left them seriously dry, lubed and reassembled with new circlips Click image to enlarge Next I refitted the oil squirt jets with a spot of loctite and torqued to spec (not pictured) then I fitted the crank shaft using new bearings and thrust washers. Mains need new bolts as they are stretch fit. Torqued to a nm setting then an angle. Here I tried to use a cheapo angle metre but it was awful so I hit ebay. Got really lucky on a beta digital metre which was listed as an 'angel meter' so attracted no bids Crank endfloat checked with the DTI
Click image to enlarge Next up pistons going in with new rings having checked the ring gaps and alignment against specs, again you need new bearing shells and bolts on these. Click image to enlarge Last one
Click image to enlarge Now things got annoying ! The last bolt on the big end rounded so I got on the blower to Turner who were great in sending me out a replacement. This was all good until I pulled the oil pump apart Click image to enlarge All measured up fine and got a good cleaning, popped it back together and every bolt torqued up fine until the last one which nipped and promptly stripped  Purchased some identical 20mm torx headed stainless bolts in M5 and a high quality tap to try and rectify this.
So now all the measuring is done it should be fairly quick to reassemble fully this weekend. Have also spoken to Alive tuning to find out about a VNT turbo and intercooler, not having got any luck contacting IRB. |
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22nd May 2015 4:39pm |
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| Welkman Member Since: 02 Nov 2014 Location: Essex colchester Posts: 332
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Fully built up on the stand now, new clutch master and slave cylinders fitted, new release bearing. Nipping to the car parts place tomorrow for a alignment tool and then its going in
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27th May 2015 7:40pm |
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