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Turbo Engine Rebuild

blade7 said:
[h5]You don't want high load at low revs. And you should increase the boost gradually over the the first 1000 miles. Every factory engine has probably been run to highish revs from new. Manufacturers wouldn't do that if broke engines.[/h5]
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I'll have to disagree on that one Paul... the rings need load to bed in, perhaps using the word 'heavy' was misleading but it needs to be substantial. Foot to the floor and back off again for short bursts only, no motorway driving, no driving at constant speed until the rings are bed in
 
My mate Alex* suggested the following break-in procedure:

4th gear 30mph - floor it until you hit 70 and then let it coast back down. Repeat x10 and that’s the rings bedded in, change the oil and filter.


Then do 150-200 miles at a mix of loads and revs, still at low(ish) boost, change the oil and filter.


Go drive!

*He builds engines for the Aston Workshop that are worth more than any of our cars.
 
My race engine builder mate said, run it in hard and it makes more power. Also said it doesn't last as long though. Didn't worry him, he got paid to refresh the engines. I've run in 3 brand new engines that revved to 14k....
 
Well after going this far I have decided to try and cure a slightly noisy lifter issue whilst the engine is out. Simon over on TIPEC kindly sent me 9 good used lifters and from them and the 8 I already had we will pick the best 8 and get them stripped and cleaned. Cost new is an eyewatering £58 each and there seems little availability regardless. Compare this to the readily available new cost of less than £6 for compatible 16v lifters and it makes you shed even more tears!!

My mechanic friend has finally told me he will be starting on the rebuild and re-fit process this week (albeit not dedicated full time to it) so with a bit of luck we should now only be 2 or 3 weeks away from hearing some purring! Been a long time and can't wait!

Cheers

Stuart


 


Lovely workmanship on those sleeves and nice shiny new bespoke forged JE pistons!

Built up the balance shafts today with new bearings and bushes, alternator back on and some other bits and pieces. Play was stopped when the new waterpump was incorrect, it was blanked off for the coolant elbow. New one should arrive tomorrow and we can get the front end built up.

Also note my shiny new heat shield that was discussed on the other thread awaiting to be fitted!

Also note the new fabricated head stud my engineers made up to replace a broken one. The thread in the block also needed repaired and they have made up a stepped stud which will be stronger than ever.

All going to plan should be ready early next week to put back into car. I'm getting excited!!

Stuart
 
Would now be a really bad time to tell you that that’s how the waterpumps usually come and you drill out the hole as the material is thinner and/or demarcated in that area
 
Eldavo said:
Would now be a really bad time to tell you that that’s how the waterpumps usually come and you drill out the hole as the material is thinner and/or demarcated in that area
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Probably, lol! I will call my mechanic!! However with hindsight, there are no threaded holes to secure the plastic elbow on this one either, just a flush piece of metal, surely you can't be expected to drill and tap the threads as well???? Lol, lol, lol :ROFLMAO:

I think we'll wait and see what ECP deliver today before reaching for the power tools!!

Cheers

Stuart
 
scam75 said:


Lovely workmanship on those sleeves and nice shiny new bespoke forged JE pistons!

All going to plan should be ready early next week to put back into car. I'm getting excited!!

Stuart
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Looks good. Do you know what the piston/bore clearance is. And has anyone mentioned some piston slap from cold?
 
blade7 said:
scam75 said:


Lovely workmanship on those sleeves and nice shiny new bespoke forged JE pistons!

All going to plan should be ready early next week to put back into car. I'm getting excited!!

Stuart
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Looks good. Do you know what the piston/bore clearance is. And has anyone mentioned some piston slap from cold?
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Thanks, it does! Yeah we are standard size piston/bore clearance, 100mm pistons and 100.5mm bore clearance. Con rods have been slightly offset to minimise slap from cold.

Stuart
 
scam75 said:
blade7 said:
scam75 said:


Lovely workmanship on those sleeves and nice shiny new bespoke forged JE pistons!

All going to plan should be ready early next week to put back into car. I'm getting excited!!

Stuart
Click to expand...
Looks good. Do you know what the piston/bore clearance is. And has anyone mentioned some piston slap from cold?
Click to expand...


Thanks, it does! Yeah we are standard size piston/bore clearance, 100mm pistons and 100.5mm bore clearance. Con rods have been slightly offset to minimise slap from cold.

Stuart
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I remember back in my Cosworth days, that supposedly the Sapphire Cos had the gudgeon pins moved in the pistons to stop the idle rattle. Though JE's do still have a reputation for knocking from cold.
 
I'm sure there will still be some knocking from cold but the guys have took steps to minimise it, so can't do any more!!
 
Despite what is often stated on the internet, it seems a bit of a mystery what the original Porsche pistons are made from. The original clearances are very tight, which seems to be why there's little noise from cold. But forged pistons usually expand more than cast, so require more cold clearance. Make of that what you will...
 



Engine ready to go back into car now, when, I'm not so sure, hopefully soon!

Oil cooler assembly back on, new heat shield on, turbo back on, new water pump on (much better with cutout and holes for coolant elbow :ROFLMAO:), back belt cover on, various other heat shields and brackets on. Getting there!

Stuart




 
Just spoke to my mechanic. The engine is going back in tomorrow evening. Then we can get the head on and start bolting everything up. Home straight now!! [8D]

Stuart
 
Well some more progress yesterday, no pictures though!

Engine is back in car, head is on and torqued up. Next up is to fit the clutch and then get it timed up. My mate is snowed under today but hopefully he will get back on it on Friday. It obviously up on his ramp now (1 of 2 ramps) so we should be looking at days rather than weeks now to completion! Seems like ages but literally on the home straight now. Lots of fiddly little jobs as you can imagine, broken connectors on loom etc. to be attended to so slow and steady wins the day!

Stuart
 
Clutch is built up and reference sensors gapped when I dropped in the expansion tank and hose today. He had a job cancelled today so was getting on my car most of the day! He thinks it will be running this week then he's away for a long weekend. I'm assuming he plans to do some testing and running in as he says I'm not getting it back this week as he tidying up a lot of wiring and plumbing in and around the inlet manifold, which he plans to take his time making it all perfect. I won't complain. Still needs MOT'd as well. We get closer............

Stuart
 
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