Engine rebuild project
Posts
Post 556748 by PHIL V70R on 2012-12-27 18:37:07
watching with intrest sir...
Post 556751 by Jamest5r on 2012-12-27 18:59:47
That's the sort of price your looking at im afraid, 81.5mm forged start around that price and go upward's.
£600 plus import tax......http://www.vivaperformance.com/forged-pistons-850-s-c-v70/
Post 556753 by oblark on 2012-12-27 19:04:52
With the cost of the pistons, forged rods, shell brgs and gaskets etc this little project mite take a while to complete.
But should be able to take some serious bhp :)
Post 556754 by claymore on 2012-12-27 19:05:38
Waw, I'm glad I got my engine for £500 (even though I didn't pay for it)
Post 556756 by merc85 on 2012-12-27 19:09:42
Arrrrrrrrgh memories lol that Cylinder head brought it all back lol
Post 556757 by p fandango on 2012-12-27 19:10:29
i'd buy another block with less wear on it & stick with stock pistons
Post 556760 by Jamest5r on 2012-12-27 19:27:52
[QUOTE=oblark;556753]With the cost of the pistons, forged rods, shell brgs and gaskets etc this little project mite take a while to complete.
But should be able to take some serious bhp :)[/QUOTE]
At a rough guess i think i paid £380 for forged rods, £500 melhe pistons, plus rebore, belts etc and it all put back together i reckon about 1300 quid i paid and that's about as cheap as your gonna get.
Post 556763 by oblark on 2012-12-27 19:36:56
[QUOTE=Jamest5r;556760]At a rough guess i think i paid £380 for forged rods, £500 melhe pistons, plus rebore, belts etc and it all put back together i reckon about 1300 quid i paid and that's about as cheap as your gonna get.[/QUOTE]
That`s the sort of figure I was looking at :)
At the end of the day I will end up with a new full rebuilt engine :)
Post 556764 by Jamest5r on 2012-12-27 19:40:21
[QUOTE=oblark;556763]That`s the sort of figure I was looking at :)
At the end of the day I will end up with a new full rebuilt engine :)[/QUOTE]
Yep thats what ive got and it feels lovely might be able to nudge the high 380's/550's now i have a clutch that wont slip :)
Post 556765 by oblark on 2012-12-27 19:43:44
[QUOTE=merc85;556756]Arrrrrrrrgh memories lol that Cylinder head brought it all back lol[/QUOTE]
Do you want to port this one ??:)
Post 556770 by Wobbly Dave on 2012-12-27 19:59:12
Having just been through the process - I was kinda lucky with the forged pistons - in so much that they came from an abandoned project. 81.5mm forged wiseco pistons cost me 500 quid. The rods (as recommended by Smithy) - K1 technology from Co-ordsport - were 500 ish. Donor engine - is not a problem as you already have one. A local cylinder head specialist refurbished the head & rebuilt the refurbished & rebored block for a very reasonable 1300 quid
HTH
Post 556783 by oblark on 2012-12-27 20:14:37
[QUOTE=Wobbly Dave;556770] A local cylinder head specialist refurbished the head & rebuilt the refurbished & rebored block for a very reasonable 1300 quid
HTH[/QUOTE]
The head that was on the engine has 6 bent exhaust valves so I got a refurbed head from Dalhousie and I will rebuild the engine block myself as I`ve done a few in my time :)
Post 556807 by Wobbly Dave on 2012-12-27 21:07:40
Super, great - smashin. I would have re-assembled it myself but the VVT cam gave me the wibblies.
Post 556933 by oblark on 2012-12-28 17:50:17
Removed the main brg shells today and checked the brgs journals for size.
The brg journals are standard size :smile:
The block has a B stamped on it for the brg classification and I think the crank has a C stamped on it for the brg classification,
So in the Haynes book of lies the brg shells should have a yellow mark on them but I can`t find any marks but I did find some part numbers,
Thrust brg 9146180 and 9135850
Main brgs 9146170 and 9135840
Can someone check/no a web site that lists the part No. to confirm brg sizes :smile:
Post 556945 by Jamest5r on 2012-12-28 18:41:17
[QUOTE=oblark;556933]Removed the main brg shells today and checked the brgs journals for size.
The brg journals are standard size :smile:
The block has a B stamped on it for the brg classification and I think the crank has a C stamped on it for the brg classification,
So in the Haynes book of lies the brg shells should have a yellow mark on them but I can`t find any marks but I did find some part numbers,
Thrust brg 9146180 and 9135850
Main brgs 9146170 and 9135840
Can someone check/no a web site that lists the part No. to confirm brg sizes :smile:[/QUOTE]
Pault5estate had a load of info on shell's etc from when he done his its a very complicated mine field, mine looked ok so didnt mess lol.
Post 556970 by LiamT4 on 2012-12-28 20:01:23
[QUOTE=Jamest5r;556764]Yep thats what ive got and it feels lovely might be able to nudge the high 380's/550's now i have a clutch that wont slip :)[/QUOTE]
Do you mean 380bhp/550nm? Surely after all that work the engine could take a lot more?
Post 570832 by claymore on 2013-02-07 19:19:34
looking good mate
Post 589572 by oblark on 2013-03-28 16:04:33
Haven`t done much to the engine rebiuld for a while,
Managed to get hold of 4 B4204T5 pistons ( 4 more next month )
Had some spare time today so I`ve tapped the PCV return hole ready for a 1/4 bsp blank and machined up a plug to go in the main block vent.
Post 593698 by oblark on 2013-04-06 21:24:02
Made the most of the sunshine today and started to paint the head/cam cover
Also drilled a hole in the spark plug cover for the breather
Post 600386 by oblark on 2013-04-25 20:11:06
Had some spare time so I drilled 15 lightning holes flywheel. :)
As soon as I`ve got Pedro`s light weight crank the pair of them will be dynamically balanced.
Post 600393 by M-R-P on 2013-04-25 20:23:33
Nice work there Rob. It's all coming together nicely ;)
Post 600865 by AndysR on 2013-04-27 13:12:11
Nice work, I like the cam cover :smile:
Post 604227 by oblark on 2013-05-09 19:58:41
The stainless shim steel arrived this week so had ago shimming the liners,
I managed to two bits of shimming in the gap,
To stop it from coming out the ends where bent over and loctited :)
Post 604234 by claymore on 2013-05-09 20:05:36
Nice job mate, that will work nicely
Post 604258 by Jamest5r on 2013-05-09 20:39:55
Very neat :)
Post 604276 by t5 pete on 2013-05-09 21:23:47
Very nice what grade stainless did you go for the shims.
Post 604279 by oblark on 2013-05-09 21:38:34
[QUOTE=t5 pete;604276]Very nice what grade stainless did you go for the shims.[/QUOTE]
The stainless shim is 316,
Post 604286 by M-R-P on 2013-05-09 22:28:33
Top work as always mate ;) she's gonna take some big boost when that lump gets fitted. You still got that supercharger? ;)
Post 604344 by oblark on 2013-05-10 08:37:32
[QUOTE=M-R-P;604286]Top work as always mate ;) she's gonna take some big boost when that lump gets fitted. [COLOR="#FF0000"]You still got that supercharger?[/COLOR] ;)[/QUOTE]
Yes and I`m not fitting it :)
Post 604346 by claymore on 2013-05-10 08:46:40
Did someone mention Supercharger, wouldn't be an M62 would it?
Post 604353 by oblark on 2013-05-10 09:11:53
[QUOTE=claymore;604346]Did someone mention Supercharger, wouldn't be an M62 would it?[/QUOTE]
All I now is it came out of a C180 coupe merc :)
Post 604355 by claymore on 2013-05-10 09:22:00
[QUOTE=oblark;604353]All I now is it came out of a C180 coupe merc :)[/QUOTE]
M45 then.
Post 609208 by Jamest5r on 2013-05-22 20:26:09
Nice work :) looks bloody tight at one point lol, so when you gonna fit this?
Post 609211 by oblark on 2013-05-22 20:31:47
[QUOTE=Jamest5r;609208]Nice work :) looks bloody tight at one point lol, so when you gonna fit this?[/QUOTE]
It just clears the steering rack surport by 3/8 inch :)
I`ve still got to get hold of another piston then it`s off to the engineers to be rebored to 2.4
Hopefully will be ready to go in the car later this year :)
Post 609226 by V70 Graham on 2013-05-22 20:58:53
Nice work Rob, some great builds should be finished this year.
Post 609228 by Wobbly Dave on 2013-05-22 21:01:30
you ditching the rear gearbox mount?
Post 609234 by oblark on 2013-05-22 21:11:05
[QUOTE=Wobbly Dave;609228]you ditching the rear gearbox mount?[/QUOTE]
No, it`s under the compressor housing :)
Post 609240 by merc85 on 2013-05-22 21:18:44
Looks flippin good bud :)
Post 609245 by oblark on 2013-05-22 21:25:19
[QUOTE=graemewelch;609237]nice work there. but if id known i could of sorted you a flange rather than cut up a cat
bit cheeky like but do you do much machining. always looking for some one to do a few jobs[/QUOTE]
I only had the downpipe to the flexi joint :)
I do abit of basic machining as and when I need to do some and when I`m in the workshop.
If I need anything more complex I know a good machine shop :)
Post 609246 by smithy on 2013-05-22 21:27:44
What turbo is that mate
Post 609248 by oblark on 2013-05-22 21:31:50
[QUOTE=smithy;609246]What turbo is that mate[/QUOTE]
It`s a k24 :)
Post 609253 by Wobbly Dave on 2013-05-22 21:39:28
[QUOTE=oblark;609234]No, it`s under the compressor housing :)[/QUOTE] I see the rubber part - but usually that's connected to the gearbox via a bracket
this is Paul t5 estates...
Post 609256 by Kingsford G on 2013-05-22 21:44:01
Nice work mate.looking forward seeing what it puts out,gotta be well quick and lots of fun with an mbc
Post 609259 by oblark on 2013-05-22 21:47:38
[QUOTE=Wobbly Dave;609253]I see the rubber part - but usually that's connected to the gearbox via a bracket
this is Paul t5 estates...
[/QUOTE]
As I will using the M66 gearbox I had to make my own rear gearbox mount :)
Post 609260 by Wobbly Dave on 2013-05-22 21:48:27
Aaahh! I wondered why I couldn't see it LOL
Post 609824 by oblark on 2013-05-24 20:26:13
I dropped into the machine shop to see if any of the bits & bobs I`m having made where finished,
And this was finished
More to follow :)
Post 610141 by oblark on 2013-05-25 20:00:02
Finished the downpipe off today and made a tool to lock the cams in place :)
Post 612993 by Wobbly Dave on 2013-06-02 19:43:14
loving your work.
Post 612994 by claymore on 2013-06-02 19:45:46
Looking really good :)
Post 613010 by Tomcat on 2013-06-02 20:17:54
Loving this thread, looking forward to seeing it fitted.
Post 618677 by oblark on 2013-06-21 20:06:25
Quick update, made a start on the stainless RIP kit, The blue piece of pipe is where the DV mite be going :wink:
Post 618679 by stribo on 2013-06-21 20:20:30
Looking good Rob, I wish you'd hurry up and finish it, so you can bolt it up to my car. ;)
Post 618684 by oblark on 2013-06-21 20:33:47
[QUOTE=stribo;618679]Looking good Rob, I wish you'd hurry up and finish it, [COLOR="#FF0000"]so you can bolt it up to my car[/COLOR]. ;)[/QUOTE]
In your dreams :)
Post 618688 by martybelfastt5 on 2013-06-21 20:38:29
looking good!!!
Post 618727 by AndysR on 2013-06-21 22:03:35
Nice one, making some great progress with it, once question and if I have missed your reasoning I apologise.. Why T4 pistons?
Post 618749 by Wobbly Dave on 2013-06-21 23:18:47
I thought it was to lower the compression?
Post 618751 by M-R-P on 2013-06-21 23:23:42
The T4 pistons (I can't remember which incarnation) were just the right size to accomodate the bores (can't remember if it's to cope with wear or a rebore).
Coming on nicely there mate. You'll have to do a build video with the A-Team music :)
Post 618805 by oblark on 2013-06-22 06:40:47
[QUOTE=AndysR;618727]Nice one, making some great progress with it, once question and if I have missed your reasoning I apologise.. Why T4 pistons?[/QUOTE]
The reason I'm using second hand t4 pistons is they easy to get hold of and are cheaper than 850 oversize pistons :)
Post 624723 by Wobbly Dave on 2013-07-12 12:05:00
I am beginning to wonder if it would not be easier to convert my ME7 back to a manual throttle - as I am beginning to lose my rag with on-demand systems.
Post 679928 by oblark on 2014-01-12 19:48:33
I thought i would update this thread :)
Fitted the RN crank and checked the bearing clearance,
The clearance of the main bearings is between 1-2 thou radial clearance :)
Post 679976 by p fandango on 2014-01-12 20:43:59
good to hear it fitted with no issues, don't suppose you weigh'd it & your old crank for comparison did you?
Post 679997 by oblark on 2014-01-12 21:22:26
[QUOTE=graemewelch;679994]what the end of the manifold cut off for[/QUOTE]
The ME7 inlet manifold had to be cut back to allow it to clear the PAS pump
Post 679998 by t5 pete on 2014-01-12 21:23:16
[QUOTE=graemewelch;679994]what the end of the manifold cut off for[/QUOTE]
Its because it fouls the power steering pump
Post 680035 by MoleT-5R on 2014-01-13 05:10:07
excellent thread, just been back and re-read it, a lot of food for thought, keen to see the results when finished, keep up the good work
Post 680074 by oblark on 2014-01-13 13:18:28
I was going to use hylomar on faces of the block to intermediate section and to the sump or would I be better off use a gasket sealant ?
Post 680077 by 960kg on 2014-01-13 14:21:48
[QUOTE=oblark;680074]I was going to use hylomar on faces of the block to intermediate section and to the sump or would I be better off use a gasket sealant ?[/QUOTE]
This is a great thread......very well done and the clarity of the pictures.
We used to use Hylomar in the `60s it was used also by Rolls Royce to assemble there engines and is still the best.
Having said that because the white block is in 5 different sections Volvo`s special adhesive applied with a roller not only seals but acts as a glue and therefore sticks the whole lot together for block strength which will not flex.
Seeing as you have paid out a bit on parts plus all the work it would be silly i think that just for the sake of £30 odd to spoil the efforts.
Especially with the horses i expect this engine will produce you want it as a solid block with no chance of flexing. As you know the two halves of the main and camshaft bearing supports are the actual alloy block and not as old school bearing caps!!
Good luck with what you choose to do.
Post 680097 by p fandango on 2014-01-13 18:26:42
Have u ported the head to match the newer me7 manifold?
Post 680112 by oblark on 2014-01-13 18:48:03
[QUOTE=p fandango;680097]Have u ported the head to match the newer me7 manifold?[/QUOTE]
The port shape on the head is the same as the me7 inlet manifold.
The ports in the head will smoothed and polished :)
Post 680225 by iancho on 2014-01-14 08:10:27
Really interesting, keep up the good work Rob :smile:
Post 680639 by oblark on 2014-01-15 20:49:20
A set of piston rings where ordered today, also phoned FRF and ordered the o rings and gaskets to rebuild the bottom end.
Hopefully it all should arrive by the weekend :)
Post 680656 by Biff on 2014-01-15 21:23:40
Glad your going for it rob.
Beast. :)
Post 681542 by p fandango on 2014-01-18 19:40:01
[QUOTE=oblark;681526]
[/QUOTE]
they look identical to ME7 short skirt pistons, what length rods you running?
Post 681544 by oblark on 2014-01-18 19:45:16
The pistons came from 2 x V40 T4 2.0 litre
The rods are 139.5 m/m long
Post 681837 by oblark on 2014-01-19 20:44:43
Here is a short video of the rebuild so far.....
[video=youtube_share;BhtwuxeF0z0]http://youtu.be/BhtwuxeF0z0[/video]
And here is a preview of what the sngine will look like when finished...
Post 681842 by graemewelch on 2014-01-19 21:04:14
looking good. thought you might of went for a 3" down pipe
Post 681847 by oblark on 2014-01-19 21:08:11
[QUOTE=graemewelch;681842]looking good. thought you might of went for a 3" down pipe[/QUOTE]
It is a 3" down pipe :)
Post 682007 by graemewelch on 2014-01-20 13:16:38
[QUOTE=oblark;681847]It is a 3" down pipe :)[/QUOTE]
sorry my mistake. at first glance i thought it was a straight flange. just thought after all the effort thats been put in why would he restrict it with a 2.5" exhaust. ill look closer next time befor opening my mouth
Post 682016 by M-R-P on 2014-01-20 13:34:16
Liking the music off the video Rob, and the editing skills are coming on too :)
Keep it up dude ;)
Post 682020 by V70 Graham on 2014-01-20 13:36:33
[QUOTE=M-R-P;682016]Liking the music off the video Rob, and the editing skills are coming on too :)
Keep it up dude ;)[/QUOTE]
Wot he said, liking the video mate.
Post 682022 by stribo on 2014-01-20 13:36:54
Ooo, shiny, would look good in my C70.;)
Post 682061 by S70T5Chris on 2014-01-20 17:40:50
Nice bit of Rob Zombie!! Cool vid mate, keep it coming I say!
Post 682187 by AndysR on 2014-01-20 21:20:05
Good to see things kick started again, did (will) you hone the bores or is it all as removed?
Post 682314 by Harvey on 2014-01-21 07:25:54
So is a new oil pump on the way as it's missing or just waiting for the gaskets set to turn up.
Post 684434 by merc85 on 2014-01-26 16:29:37
Looks great buddy well done mate :)
Post 684435 by JT on 2014-01-26 16:33:45
looks fantastic! nice work! :B_thumb:
Post 684436 by S70T5Chris on 2014-01-26 16:33:58
That is looking fantastic Rob.
Post 684441 by V70 Graham on 2014-01-26 16:50:18
Looking good mate, shouldn't be too long now before it's all done.
Post 684444 by abdul on 2014-01-26 16:52:28
Very nice keep the good work up
Post 684469 by M-R-P on 2014-01-26 18:05:25
Big shiny thingy :)
It'll look great in a modified Honda 400-4 frame ;)
Post 684479 by graemewelch on 2014-01-26 18:12:38
looks good. any pics of the head work. its a job ill be doing shortly. a new head is on its way
Post 684496 by Shinsplintz 101 on 2014-01-26 18:29:48
Really enjoyed this thread - my technical expertise begins & ends atm with changing the boot struts! One day i'll have a bash at rebuilding one of those big oily things, in the mean time it's nice to watch from the side-lines! Liking the satin black look too - nicely understated.
Keep up the good work, all the best, Morgan
Post 684514 by Wobbly Dave on 2014-01-26 19:02:38
I hope it runs as good as it looks.
Post 684527 by Biff on 2014-01-26 19:53:53
Looks like I may have to join you & Steve on the engine builds.
Very impressed with the finish on the engine rob, it's better than oe.
Will certainly be using this thread for reference.
Post 684548 by AndysR on 2014-01-26 20:41:34
How good does that look! Love the black head/rocker cover look, bet you can't wait to get it fitted and running now with so little left to do :)
Post 688337 by artfulflounder on 2014-02-09 14:51:16
Any progress......you got the engine in and running yet?
Post 688391 by AndysR on 2014-02-09 18:09:44
What he said ^^^
Post 689264 by dant5r on 2014-02-13 16:32:47
https://m.facebook.com/groups/692214850823998
Came across this today on Facebook.
Is this same guy building this engine.
Post 689272 by claymore on 2014-02-13 16:54:33
That link makes no sense to me?
Post 689298 by M-R-P on 2014-02-13 19:04:00
[QUOTE=dant5r;689264]https://m.facebook.com/groups/692214850823998
Came across this today on Facebook.
Is this same guy building this engine.[/QUOTE]
yes mate, that's Robs build, half way down the page.
Post 689474 by p fandango on 2014-02-14 20:29:12
looks good, but i can't believe your doing all that work & using a normal T-5 manifold
Post 689477 by oblark on 2014-02-14 20:32:44
[QUOTE=p fandango;689474]looks good, but i can't believe your doing all that work & using a normal T-5 manifold[/QUOTE]
The T5 manifold is just being used to mock up the turbo :) I`ve got a S60R manifold on the car at the moment :)
Post 689479 by p fandango on 2014-02-14 20:35:35
[QUOTE=oblark;689477]The T5 manifold is just being used to mock up the turbo :) I`ve got a S60R manifold on the car at the moment :)[/QUOTE]
thats ok then ;)
Post 689499 by AndysR on 2014-02-14 22:00:17
Looks good so far :)
Post 689503 by smithy on 2014-02-14 22:17:48
Looks very nice mate and should push some good power too
Post 689506 by Wobbly Dave on 2014-02-14 22:24:10
Loving your work - a word of warning - make sure if you've painted the gearbox that the mating surfaces are paint free. I had that issue & the car wouldn't start/run properly because it interfered with engine earthing.
Post 689508 by artfulflounder on 2014-02-14 22:33:19
I'm a miserable git I don't do facebook....so its good to see you're getting on well.
will be good to see the results when you start tinkering with the ecu.
Post 689552 by 960kg on 2014-02-15 09:52:36
Showing my ignorance here i expect but what gearbox is that as the change levers are different on my `97 M56 manual box??
Post 689555 by M-R-P on 2014-02-15 10:10:12
Focus ST gearbox mate ;)
Post 689579 by MoleT-5R on 2014-02-15 12:25:09
Rob made his own linkage mounts in this thread a while ago iirc http://www.vpcuk.org/forums/showthread.php?49587-6-speed-gear-upgrade
Post 689580 by stribo on 2014-02-15 12:31:21
I recognise that gearbox ;) Good work mate.
Post 689629 by oblark on 2014-02-15 16:48:33
[QUOTE=M-R-P;689555]Focus ST gearbox mate ;)[/QUOTE]
Yeah and it`s got volvo cast on the bellhousing :)
Post 689630 by Harvey on 2014-02-15 16:54:35
[QUOTE=oblark;689629]Yeah and it`s got volvo cast on the bellhousing :)[/QUOTE]
So it's a Volvo gearbox that was fitted to a Ford ST.
This tread makes a good read.
Post 689633 by oblark on 2014-02-15 17:01:04
When I brought the gearbox a focus ST gearbox on ebay was around £170 but a gearbox out of a volvo was around £300.
Post 689635 by p fandango on 2014-02-15 17:13:58
[QUOTE=oblark;689633]When I brought the gearbox a focus ST gearbox on ebay was around £170 but a gearbox out of a volvo was around £300.[/QUOTE]
I picked a focus box up for £50, can't remember who I sold it too
Post 689676 by MoleT-5R on 2014-02-15 20:04:36
other than the extra gear (but the same final drive as far as I see), is there any advantage over the 10valve box ? or am I looking at it wrong?
Oh and if anyone see's a awd m66 going for a reasonable sum let me know please
Post 689680 by p fandango on 2014-02-15 20:33:55
[QUOTE=MoleT5-R;689676]Oh and if anyone see's a awd m66 going for a reasonable sum let me know please[/QUOTE]
according to my list there are 4 different ratios (with 3 different fdr's) available in the M66 AWD box, so think you'll have to find the right one to match the diff ratio on your rear axle
Post 689684 by MoleT-5R on 2014-02-15 20:41:35
[QUOTE=p fandango;689680]according to my list there are 4 different ratios (with 3 different fdr's) available in the M66 AWD box, so think you'll have to find the right one to match the diff ratio on your rear axle[/QUOTE]
oh that throws a spanner in the works, I haven't a clue what fdr the V70R is running, but will have to find out what it has, thanks for the heads up
Post 689686 by p fandango on 2014-02-15 20:50:25
[QUOTE=MoleT5-R;689684]I haven't a clue what fdr the V70R is running[/QUOTE]
4.00:1
Post 689910 by partsforvolvos.com on 2014-02-17 11:25:29
I read with interest (not often for me) the feature a few issues ago in the voc magazine where somebody fitted a m66 to their d5 to get better motorway consumption.
the thing that intrigued me that I was not aware of was the m66 box apparently has relay control switching for the shift block so you cant select the wrong gears at high speed.
the person who wrote the feature was not able to resolve this, and thought it would be ok if careful when driving.
interested to know, have you heard of this, and do you plan a resolution to it when your box is installed rob?
the engine looks really nice btw
Post 689923 by oblark on 2014-02-17 13:29:35
The switch/solenoid is mounted on the gear stick not on the gearbox, so it isn`t a problem :)
Post 691043 by oblark on 2014-02-22 20:32:28
downpipe and decat pipe have been heat wrapped :)
Post 691048 by stribo on 2014-02-22 20:39:29
Nearly ready to go in my car then ;) Great work mate, can't wait to see your car in action once the new set up's fitted. Any plans for taking it up the strip? Might be the car to knock Dean off the top, and seeing them go head to head would be something I'd love to see.:D
Post 701922 by AndysR on 2014-04-08 19:59:53
How's this coming along now Rob? :)
Post 701928 by oblark on 2014-04-08 20:10:17
[QUOTE=AndysR;701922]How's this coming along now Rob? :)[/QUOTE]
Just waiting for my PPI payout then I`ll be ordering the head gasket, head bolts, water pump and timing belt from Volvo
Then it`s just a case of swapping engine/gearboxes over :)
Post 701945 by AndysR on 2014-04-08 20:35:27
Nice one :)
Post 706629 by oblark on 2014-04-26 21:17:00
As I was cleaning the engine bay today I thought it would be a good time to measure up for the 3.25" maf
I made up a cardboard template to make sure it would fit :)
Just need to get it made out of 3mm aluminium.
Post 711742 by oblark on 2014-05-14 19:49:07
This little lot arrived in the post today :)
Head gasket, head bolts and turbo gaskets/copper washer from FRF Volvo
Water pump, timing belt and damper from PFV
All ordered on Monday, very quick delivery :)
Post 713228 by oblark on 2014-05-20 19:26:13
The new MAF mounting plate was picked up today and the ramair filter arrived in the post.
Starting to come together :) just waiting for 3" pipe work to turn up so the MAF to turbo pipe can be made up.
Post 713234 by smithy on 2014-05-20 19:52:46
That look nice mate
Post 713263 by AndysR on 2014-05-20 22:21:48
Nice filter, that shouldn't restrict much.. :)
Post 713273 by M-R-P on 2014-05-20 23:02:07
Bout time you got rid of that tiny cone filter mate, gonna look sweet under the bonnet with that.
Post 713279 by V70 Graham on 2014-05-20 23:22:30
Nice looking bit of kit mate.
Post 713729 by oblark on 2014-05-22 20:24:48
Had a spare few hours this afternoon after work so I`ve started to mock the new 3" MAF to turbo pipe.
It still a little be of tiding up which I`ll do over the weekend :)
Post 713731 by theflyingbrick on 2014-05-22 20:33:19
looking good rob,im liking the battery idea....saves moving it to the boot for some more space ;)
Post 713736 by M-R-P on 2014-05-22 20:52:49
Shiny shiny :)
Post 713738 by stribo on 2014-05-22 20:55:45
Looking good Rob, that's going to sound mean with the new filter.
Post 713745 by Kingsford G on 2014-05-22 20:58:41
[QUOTE=oblark;713729]Had a spare few hours this afternoon after work so I`ve started to mock the new 3" MAF to turbo pipe.
It still a little be of tiding up which I`ll do over the weekend :)[/QUOTE]
Thats one nice looking engine bay mate,well done.
Post 713748 by oblark on 2014-05-22 21:01:49
[QUOTE=Kingsford G;713745]Thats one nice looking engine bay mate,well done.[/QUOTE]
Just wait to this little gem has been fitted :)
Post 713750 by Kingsford G on 2014-05-22 21:02:56
[QUOTE=oblark;713748]Just wait to this little gem has been fitted :)
[/QUOTE]
Just getting better mate.Is it K24 bolted on it?
Post 713751 by M-R-P on 2014-05-22 21:04:27
[QUOTE=oblark;713748]Just wait to this little gem has been fitted :)
[/QUOTE]
Rob, stop posting such filthy porn!
Post 713763 by oblark on 2014-05-22 21:44:48
[QUOTE=Kingsford G;713750]Just getting better mate.Is it K24 bolted on it?[/QUOTE]
Yeap thats a K24 :)
Post 713806 by Kingsford G on 2014-05-23 07:29:01
[QUOTE=oblark;713763]Yeap thats a K24 :)[/QUOTE]
I really like k24,quick spool up and smooth.Sorry I didn`t follow this thread,what car is the engine going in?
Post 713807 by oblark on 2014-05-23 07:33:27
[QUOTE=Kingsford G;713806]I really like k24,quick spool up and smooth.Sorry I didn`t follow this thread,what car is the engine going in?[/QUOTE]
My 850, I went for the K24 as I think it is a under rated as a turbo & not many people are using the K24 in a 850.
Post 713809 by MoleT-5R on 2014-05-23 07:45:56
Nice progress Rob, everything seems to be coming together nicely, like the new maf holder and filter
Post 713868 by partsforvolvos.com on 2014-05-23 12:47:19
progress looks good rob, carry on!
Post 713882 by martybelfastt5 on 2014-05-23 14:52:49
looks awsome pitty the bodywork will hide most of it lol
Post 714231 by Hybusamini on 2014-05-24 22:10:39
Looking good m8 keep up the good work :B_thumb::B_thumb:
Post 714393 by AndysR on 2014-05-25 20:09:34
Looking good! In fact it's looking awesome, nice work, I like the black rocker cover and twin oil cap set up :)
One question, why no S60R manifold after all the work you've done?
Post 714396 by WOODY T5 on 2014-05-25 20:13:18
[QUOTE=AndysR;714393]Looking good! In fact it's looking awesome, nice work, I like the black rocker cover and twin oil cap set up :)
One question, why no S60R manifold after all the work you've done?[/QUOTE]u don't need s60r manifolds mate me not got one :)
Post 714402 by AndysR on 2014-05-25 20:21:29
[QUOTE=WOODY T5;714396]u don't need s60r manifolds mate me not got one :)[/QUOTE]
Perhaps you should fit one then and get a lower time than you have for the last 3 years ;)
Post 714406 by stribo on 2014-05-25 20:24:44
Looking good Rob, when's it going in the car?
Post 714409 by WOODY T5 on 2014-05-25 20:29:16
[QUOTE=AndysR;714402]Perhaps you should fit one then and get a lower time than you have for the last 3 years ;)[/QUOTE]might just wait till someone beats me hope there still sale them in 3 years time lol
Post 714411 by oblark on 2014-05-25 20:29:39
[QUOTE=stribo;714406]Looking good Rob, when's it going in the car?[/QUOTE]
After the flywheel comes back from being balanced so it shoiuld be in the car by the next southern meet :)
Post 714413 by oblark on 2014-05-25 20:31:29
[QUOTE=AndysR;714393]Looking good! In fact it's looking awesome, nice work, I like the black rocker cover and twin oil cap set up :)
[COLOR="#FF0000"]One question, why no S60R manifold after all the work you've done[/COLOR]?[/QUOTE]
I will be using the RN exhaust & inlet manifolds on the rebuilt engine :)
Post 714427 by claymore on 2014-05-25 20:45:32
[QUOTE=oblark;714413]I will be using the RN exhaust & inlet manifolds on the rebuilt engine :)[/QUOTE]
It's one of these you want :)
Post 714429 by stribo on 2014-05-25 20:48:53
[QUOTE=claymore;714427]It's one of these you want :)
[/QUOTE]
And the space to fit it. :P
Post 715919 by stribo on 2014-05-31 19:07:06
Nice, that flywheel looks seriously lightened. :)
Post 723874 by oblark on 2014-07-12 20:23:09
I thought I would update this thread,
The engine went in about a month ago and I've had a deride of time with it since.
First of all ALL the gaskets, o rings, oil seals and copper washers that where fitted to the engine when it was rebuilt are genuine Volvo parts.
I've spent the last month chasing oil leaks.
First to leak was the rear main seal (I damaged the seal fitting it)
Then turbo drain pipe started to leak a week after the engine was fitted, the oil feed pipe to the turbo was next to leak (it's now on it's 4 set of copper washers) all the cam oil seals have been changed, the 3 covers on the back of the engine for the piston oil cooling jets started leaking last weekend, the dip stick tube, oil pressure switch have all had they seals changed and to top it off the engine started to burn oil after only doing 300ish miles which has filled the exhaust with burnt oil and has knackered the O2 sensor,
I've done a compression test on a hot engine and got a balanced 12 bar, poured some oil in the bores and the readings came up to 16 bar so it looks like the new rings are letting by. As the engine is now burning oil at a hell of a rate I decided to refit the old engine, when I removed the inlet manifold I noticed that they was small puddles of oil on top of the valves which indicates that the valve stem seals are leaking but these a genuine Volvo seals and the head had been overhauled. I'll find out what is at fault when the engine is dismantled either this month or next or when I can be bothered.
So I’m running the old engine with the K24, green injectors, 3.25” maf and 6 speed gearbox. It will be mapped to start to produce boost at 3.5k and full boost at 5.5k.
With the 6 speed box it`s great to drive, 80mph @ 3000 rpm
I see why people loss the love for these car when ever weekend all you're doing is trying to keep them running.
Post 723878 by merc85 on 2014-07-12 20:33:05
Yep gets tedius mate, you must have spent a small fortune :( Sounds like it should be a Monster of a car just need to get it reliable, I know of a couple of these cars which have Sprung oil leaks running a similar set up (power wise) Were the Valve guides worn on the other engine? were they the original valves from that head?
Hope you get it sorted soon mate
Post 723879 by oblark on 2014-07-12 20:40:23
The valve guides where ok with no wear. The head has always been playing on my mind as it could have been a N/A head that has had turbo valves/guides fitted or it`s cracked/porous.
If the bores/pistons are OK then I`m going to get the original head refurbed.
Post 723881 by merc85 on 2014-07-12 20:44:37
There were 2 different diameter of Valves on the t5's early and late, was just wondering if somehow the incorect size ones were fitted at some point.
Post 723885 by oblark on 2014-07-12 20:51:04
This is the thread I started over the valves and the head.
http://www.vpcuk.org/forums/showthread.php?54882-exhaust-valves&highlight=
Post 723933 by Shinsplintz 101 on 2014-07-13 07:15:39
Real shame that - have been quietly following this thread with interest - lots of hard work & wedge gone into this one. Hope you get it sorted. Keep us posted. Cheers, morgan
Post 723942 by abdul on 2014-07-13 09:33:43
Hope u get it sorted
Post 723970 by stribo on 2014-07-13 11:58:13
Looked and sounded good yesterday Rob. :D
Post 723982 by 960kg on 2014-07-13 14:16:40
[QUOTE=oblark;723879]The valve guides where ok with no wear. The head has always been playing on my mind as it could have been a N/A head that has had turbo valves/guides fitted or it`s cracked/porous.
If the bores/pistons are OK then I`m going to get the original head refurbed.[/QUOTE]
As you know Rob i always get moaned about for my help or thoughts!.........but sitting from where i am reading your project and what you have done and are still doing those oil seals and gaskets were ok as are the stem seals and guides the problem is Old Pistons in Old Bores..... it does NOT work!!!!........you may have had the T4 pistons fitted to a rebored bore but it will NOT work!
I have built so many engines i can`t remember them all but the only ones that were 100% ok were new rebored blocks with new pistons and that was only for producing 120bhp in the early `70`s!
As you know pistons are not parallel they are tapered a worn piston even more so where do you start the measuring for it to fit !!........some say 10mm down some say at the bottom of the stroke for measuring the block to piston clearance.
There are different grades of piston and bores when new in the factory for fit which only differ by a few thou so how can a used 2nd hand used piston give performance bhp with no problems .......it simply can`t......
The reason your oils seals have failed is because you have too much blowpast which gave you too much pressure in the sump even tho you have modified the PCV.
It is not normal for ALL the seals to go is it especially pucker Volvo?
I don`t know if you have figures but bore is 83.015 and piston should be 82.995 with a running clearance of 0.20mm ( 7 to 8 thou)
Minimum is 4 thou and the max is 11 thou running clearance.
Also did you know that the 1st compression ring is larger than the 2nd compression ring.......did you fit them the wrong way around??
Good Luck
Keith
........................................................................
Post 723987 by t5 pete on 2014-07-13 14:31:16
sorry but I must dissagree with you your first paragraph is wrong I know this may suprise you but I actually agree with you just goes to show these old ones still have it
Post 723996 by oblark on 2014-07-13 15:31:29
[QUOTE=960kg;723982]As you know Rob i always get moaned about for my help or thoughts!.........but sitting from where i am reading your project and what you have done and are still doing those oil seals and gaskets were ok as are the stem seals and guides the problem is Old Pistons in Old Bores..... it does NOT work!!!!........you may have had the T4 pistons fitted to a rebored bore but it will NOT work!
I have built so many engines i can`t remember them all but the only ones that were 100% ok were new rebored blocks with new pistons and that was only for producing 120bhp in the early `70`s!
As you know pistons are not parallel they are tapered a worn piston even more so where do you start the measuring for it to fit !!........some say 10mm down some say at the bottom of the stroke for measuring the block to piston clearance.
There are different grades of piston and bores when new in the factory for fit which only differ by a few thou so how can a used 2nd hand used piston give performance bhp with no problems .......it simply can`t......
The reason your oils seals have failed is because you have too much blowpast which gave you too much pressure in the sump even tho you have modified the PCV.
It is not normal for ALL the seals to go is it especially pucker Volvo?
I don`t know if you have figures but bore is 83.015 and piston should be 82.995 with a running clearance of 0.20mm ( 7 to 8 thou)
Minimum is 4 thou and the max is 11 thou running clearance.
Also did you know that the 1st compression ring is larger than the 2nd compression ring.......did you fit them the wrong way around??
Good Luck
Keith
........................................................................[/QUOTE]
If you look you can make out a puddle of oil on top of the valve heads and where it has come out of the inlet ports.
When I was younger a mate of mine rebuilt his 2 stroke motorbike engine and forgot to refit the rings, it smoked abit but it ran.
Post 724057 by 960kg on 2014-07-13 20:44:55
[QUOTE=oblark;723996]
If you look you can make out a puddle of oil on top of the valve heads and where it has come out of the inlet ports.
When I was younger a mate of mine rebuilt his 2 stroke motorbike engine and forgot to refit the rings, it smoked abit but it ran.[/QUOTE]
I understand the 2 stroke bit as that is where i started my tuning engines ,i had the Lambretta GT 200 in 1964 ....it had the hemi head design just like Aston Martin and Jaguar so that is where it all started with me and engines.....the 2 stroke will smoke because of the oil mix in the fuel as it doesn`t have a sump for oil!
Not arguing at all Rob as i know you know your engines etc. but why is there oil on the manifold flange gasket?.......as if it`s on the valve head that is where it should only be!....is the oil coming from the turbo?
You say the comp.test was more when you poured oil in the combustion chamber but surely it would read high if the oil was already there via the valves?
Just remembered when doing my first valve lapping in........i didn`t properly wash away all the grinding paste from the guides and after a few weeks of running the engine did smoke badly as the valve guides had worn out of this world!!
There is a problem ,only hope you find the correct answer without stripping all the time!
Post 724162 by oblark on 2014-07-14 12:49:58
The oil was only in the valve ports, the throttle and induction pipes are oil free.
I would have expected the compression reading to come up when oil was added to the bores, the higher the reading with oil over a dry test would indicate the rings are not sealing but as it only increased by 4 bar.
before the engine was removed both the pipes that go to the catch tank where vented to atmosphere and even doing that didn't stop the engine from blowing blue smoke out of the exhaust.
My money is on the head being knackered but I could wrong and have been in the past :)
Post 724183 by FIREBOLT on 2014-07-14 16:36:04
[QUOTE=oblark;612992]
[/QUOTE]
Did you wire brush the pistons to clean them?
Post 724184 by oblark on 2014-07-14 16:41:16
No, they we're cleaned with degreaser then put in dishwasher.
Post 725129 by 960kg on 2014-07-21 11:08:49
[QUOTE=oblark;724919]
As the spare turbo head I`ve got has 6 bent exhaust valves I`ll be changing over all 20 valves from one head to another (waiting for the "you can`t do that ......")[/QUOTE]
You can do whatever you want to do........but you know yourself deep down "you shouldn`t do it"..........if you want a first class engine that is!
All the time and effort and money you have spent on the engine it is only as good as it`s weakest link!
Post 725130 by partsforvolvos.com on 2014-07-21 11:13:44
keep at it rob.
this is an interesting thread, loads of threads on bodywork mods but not that many have good detail on engine rebuilds.
Post 725131 by M-R-P on 2014-07-21 11:15:27
Nice to see the Haynes book of lies being put to the use it was designed for - protecting a good table ;)
Post 725132 by oblark on 2014-07-21 11:17:01
[QUOTE=partsforvolvos.com;725130]keep at it rob.
this is an interesting thread, loads of threads on bodywork mods but not that many have good detail on engine rebuilds.[/QUOTE]
Thanks, I`ll be after some bits & bobs in the next few months :)
Post 725134 by oblark on 2014-07-21 11:19:21
[QUOTE=M-R-P;725131]Nice to see the Haynes book of lies being put to the use it was designed for - protecting a good table ;)[/QUOTE]
It was the only flat thing I could find as the valves kept falling over when sttod on the wheelie bin :)
Post 725135 by partsforvolvos.com on 2014-07-21 11:23:12
well they stopped doing the Haynes manual plastic protector wallet so the book had to be used .
we christened it the jizz cover ........ pmsl
Post 725138 by stribo on 2014-07-21 11:28:06
Surely if you lap the valves in, then there shouldn't be a problem changing them over.
Post 725139 by oblark on 2014-07-21 12:10:39
[QUOTE=stribo;725138]Surely if you lap the valves in, then there shouldn't be a problem changing them over.[/QUOTE]
The words nail and hammer spring to mind :)
As long as the valve guides aren`t worn to badly then it`s just a case of swapping valves over & lapping them in.
Post 725140 by partsforvolvos.com on 2014-07-21 12:13:30
changing valve guides is a pita, you have to heat the head to 180'c to expand it.
Post 725141 by stribo on 2014-07-21 12:18:53
[QUOTE=oblark;725139]The words nail and hammer spring to mind :)
As long as the valve guides aren`t worn to badly then it`s just a case of swapping valves over & lapping them in.[/QUOTE]
If the valve guides are worn, you'll have a problem whatever valves you put in.
Post 725142 by partsforvolvos.com on 2014-07-21 12:21:44
Volvo don't sell guides, but I managed to get some in the past ok.
Post 725275 by 960kg on 2014-07-21 20:14:57
[QUOTE=partsforvolvos.com;725130]keep at it rob.
this is an interesting thread, loads of threads on bodywork mods but not that many have good detail on engine rebuilds.[/QUOTE]
I totaly agree BUT only good engine practices should be detailed and not ones just to save money!
What secondhand valve guide on an 18year old 850 won`t have any wear?....especially a thrashed one which nobody would know of...
If the valves go side to side by too much then it does not matter what valve stems seals you put in they will be worn in miles and let the oil past which it look as though what has happened already.
So now surely the next step is new valve parts?
I have been there and got the T shirt and it don`t work successfully.....the money spent on another set of head bolts and gaskets and time you may as well spend on new valves/guides etc.
But that is only my own opinion!
Post 790831 by Uzulins on 2015-11-15 01:00:41
Very nice theread. Thanks Oblark. Loads of useful information.
After cleaning.
Also I`ve started to polish the inlet ports.
