WA: Back doors 'Boring'

[work]

Wow, cant wait to see the finished product on the dyno, though the one we used at United a while back seemed to produce lower than expected numbers for the higher powered cars there.

[trickysimon]

Looking good!

[Back Door Shenanigans.]

Haha, We will definitely do another day once shes good to go.

Wow, cant wait to see the finished product on the dyno, though the one we used at United a while back seemed to produce lower than expected numbers for the higher powered cars there.

I got quite annoyed when i looked at your thread. You're beating me

Did you go the r32 route due to the AUE or because the opportunity was there. I've got a bit of an issue getting a tune for the ecu at the moment and not sure which way to go. Would love to do R32 engine but don't have the money.

Looking good!

[Back Door Shenanigans.]

Had an interesting weekend. One of the most oh **** what the hell am i doing moments i've had with the car but all in good fun. Just need to wait until the cars running to see how screwed she is.

Anyway yesterday was all about installing the head gasket spacer and head studs. This involves removing the head and cleaning the two mating surfaces. Whilst i was there as i had to remove the timing chain i did those as well. I'm still missing the top section as its a stupid half cast version but got the lower end done.

Anyway onto the part people look at which is the photos.

So after the rocker cover is off i inspected the cams. My work has got me really paranoid about wear in engines which is helpful and hurting at the same time. But a quick look at my cams show no abrasive wear and the original machine marks still present which is a good sign. Sorry for the bad photo don't have my good camera with me.


Next i removed the upper timing chain. This involves taking the gear off the exhaust cam shaft. A little tip, Don't use a rattle gun unless you don't care about the old timing chains. It will break them (or you could take them off before but shut up).


Then the lower chain off. Did the same here and shattered the slide rail into a million little pieces. Was tossing up weather or not to change the guides but this made the decision quite easy.


Crankshaft timed. Yes its slightly off but i fixed that.


Lower chain and guides installed and mating surface cleaned up.



Before removing the head i prepped the two head gaskets that go between the head spacer. I sprayed some copper gasket spray over them which was a real PITA as they decided to keep sticking to the paper. This will be the issue if i have any but it should be ok as paper is very soft...
Before:

After:


Anyway the head finally came off and the engine gave me quite a shock. Damn she dirty.




Was really quite worried at this stage until i started the cleanup an the stuff came off pretty easily. The crap on the pistons was coming off basically with a spray of the carby cleaner.
Heres the end result. Cylinder liners are dirty but i did clean them. Residue black is the head stained. Its all flat.



Major worry i have at the moment is that all the crap off the head has and will go straight down the oil and coolant galleries. However this should be fine and the stuff is all very small and soft so it shouldn't get caught in the bearings. Note i only used a scraper and scotch brite as using sandpaper can cause a lot of issue if the particles come off into the oil galleries. However a flush of oil and coolant should clean this right up.

Head was kinda in the same condition.
With head gasket


Without head gasket


Cleaned up. I missed a bit on this as it was getting late and its very hard to clean all of the crap off but the majority is done so that should be good.


Head studs installed.


Then removed cause the gasket and spacers wouldn't go back on... sigh




Didn't get any photos of the head back on because... well that stage was late and i was frustrated.. specially as i managed to drop the first washer straight down into the sump....i hope....But i got the rest of the washers and nuts on quite painfully i don't quite like studs. I'm going to have to lift the engine, undo the sump take the washer out and then redo the sump back up as its sitting on the sump at the moment. Then i can torque all the bolts up and wait for the upper timing chain pieces. Thankfully there's still a lot of cleaning and prep work to do before that and the clutch and flywheel. But all in good time

A little update on the tune. I was thinking of going for a piggy back unit as no one does a tune for the coil pack 24v. However stealth racing in the uk has come up with an offer that cant be refused. Basically it involves me flashing my ecu with a tune, data logging and sending the data back to which they will adjust and rinse and repeat. I'm very happy about that as it will take into account any variances in the engine.

[trickysimon]

I got quite annoyed when i looked at your thread. You're beating me

Did you go the r32 route due to the AUE or because the opportunity was there. I've got a bit of an issue getting a tune for the ecu at the moment and not sure which way to go. Would love to do R32 engine but don't have the money.

Sorry, completely missed this!
To be honest, it was mostly because the opportunity was there. That being said, if I was to do it again, I would use the R32 engine regardless of cost. As you know, makes finding parts and tunes etc much easier, not to mention the VVT and monster head ports

Awesome progress!

[trickysimon]

Clear out your inbox btw

[Back Door Shenanigans.]

YAY! got the freaken washer out of the sump without having to take it off.

[RolfGolf]

YAY! got the freaken washer out of the sump without having to take it off.

Small victories make it all worthwhile

[work]

Thanks for showing us the progress pics! Once you've finished on yours can you clean mine out

[Back Door Shenanigans.]

Not along of progress lately, just waiting on timing chain parts coming from germany and a clutch and flywheel. Then i can start putting the engine back together and start building the exhaust.

Just cleaning up some pieces.

Rocker Cover before.

Timing guides before



After



And painted.




Also decided that i would take apart my old head unit to see if i could clean it up and get it working. Wow was there a lot of coke syrup type stuff all underneath the screen. No wonder it was screwing up. No good photos though. Hopefully it works again when i can power it back up. Otherwise its a much cheaper replacement screen at only $180 compared to $850