well after 8000 miles of happy motoring on the engine i built for the RX7 i had the misfortune of coming across a very cheap black one with a blown engine (had you all going there didnt i? haha)
Here are the pics from day 1
The start:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/DSC00071.jpg)
the end
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/DSC00075.jpg)
and what happens when you dont have an impact gun and have to remove a free spinning pulley:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/DSC00074.jpg)
Next is drain fluids, disconnect coolant and oil cooler pipes, exhaust, pull ECU cable, undo engine mounts and trans and out she comes.
lol, nice one :p
can you do mine next :D
oooohhhhh looks like fun
so whats the plan - rebuild and keep or sell on ??
Rebuild and sell on. Its a pretty mint car...its an Auto; but some people like that.
Shafster - if you want me to yes i can! :)
Nice, I plan on doing the same once I\'ve got mine running 100% :)
Quote from: BobfishShafster - if you want me to yes i can! :)
might take you up on that one day mate..... it\'s driving minty at the moment though :)
more today, havent had chance to work on it since day 2.
Auto\'s are different to manuals and a bit of a bitch to get the engine out!
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/DSC00091.jpg)
took downpipe off with engine in car this time, much easier!
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/DSC00092.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/DSC00093.jpg)
Torque converter
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/DSC00094.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/DSC00095.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/DSC00096.jpg)
:D
Good luck with it :)
Thanks man :)
P.s, this car will be for sale after the rebuild.
good one mate, how easy is it to do a rebuild. i would love to have the guts to attept it. must be a forking load cheaper aswell.
Its a piece of pee pee, just be meticulous and careful, take your time.
Good luck, bobfish :Thumbs-up
I\'ve just finished putting a motor back in mine, and about to start rebuilding the one that came out. Wish I\'d taken some pics while I was doing it now.. Jitesh should be sending the flywheel tool out soon, he just mailed me to ask if it\'s ok to send on to you. If you like it as well I\'ll make some more for sale to club members through a vendor, (will be fairly cheap) or maybe just donate a couple to the club.
Anyway, hope all goes well. If I get stuck with my rebuild would you mind giving me a few pointers? Did you use the DVDs, or just follow the shop manual?
All the best
Ian
Thanks Ian! And cheers for letting me borrow the flywheel tool, its a big help. im not even sure if it will work with an auto trans, but hopefully it should-worth a try!
I\'d deffo buy one if your up for making some more mate, go for it. Regards to my rebuild i used the bruce turrentine DVD and shop manual. If you get stuck (which you really shouldnt, it\'s really not hard) feel free to give me a call on 07967 511 949, email me carl.newton@affiniti.com or just sort me out a few beer tokens and ill pop up one saturday and do the engine build with you! I love working on these cars so i\'ll never turn down an opportunity to build an engine. Your not too far from me so its cool.
Good luck with your build! Remember to clean and measure everything meticulously, ESPECIALLY the coolant seal tracks.
Cheers matey :D Think I may take you up on that when I get round to it.
Likewise, if I can give you a hand with anything just let me know.
No worries with the tool, it\'s nice to see something I\'ve made being used by other people.
I\'ll get making a few up.. Not sure, but I think it should be ok with the auto, unless the ring gear teeth are different, or in a different place. Anyone know?
Btw, I had a load of trouble removing the counterweight from my second engine that had a dual plate clutch, and an auto CW. I broke a set of pullers trying to remove it with them!
I eventually worked out that I could push it off by winding bolts into the holes that bolt the flywheel to the counterweight (six holes if i remember right) and winding them in till they pushed against the back plate. I protected it with some strips of steel, and wound them in tight to put some pressure on it, then gave the end of the E shaft a small smack with a large hammer, and it popped right off. Quite a long way off, I might add.
Yours may not come to that, but I thought I\'d share my experience with it.
What do you use to check the tolerences? and where do you find this info? (if you dont mind me asking? :D)
Good luck with the build and all! :D
Thanks for that Ianvelvar, thats a right little gem im sure it will come in handy.
Rocco - you will need a dial indicator gauge with magnetic base to check tolerances on the end plates, a set of micrometers of various sizes and some calipers to measure internal dimensions (wind the calipers out then measure the calipers with a micrometer)
Tolerance info is in the factory manual. There are various sheets on the web about it too.
just wish i had a garage to do that sort of work in :(
Front room and some newspaper always work for me mate :evillaugh
Seriously, I know how you feel. I\'ve got to move out of the house I rent with a lovely double garage, and I\'m desperately looking for somewhere to buy that has enough room for me to work in. Having said that, I went from having an 800 sq ft workshop to having my garage at home, and renting another garage in the village to stash all the stuff I\'d accumulated, so guess I can adapt. I loved the workshop, but it was a right hassle keeping it secure, and it cost me so much I\'m almost stuffed for getting a mortgage. Still, I don\'t regret it. Some fun projects came out of that place. A lot of comical accidents as well, come to think of it. I DO regret not filming some of them, as it would probably have paid the rent for me.
Sorry for getting off topic and rambling..... Think I\'ll start a thread in one of the general discussion forums about commical accidents. I\'ve got a few that should amuse and delight... Mix one empty 5ft calour gas canister, one angle grinder, and one insane mate, and a desire to turn said canister into a wood burning stove.... Was one whole lotta laughs :Hammer
Todays works...im pleased with todays progress reall, i managed to get from a complete engine to this:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00099.jpg)
In only 3.5 hours!
Heres how it happened...
First victim was the turbos:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00086.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00087.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00088.jpg)
Play in the shafts is minimal
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00089.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00091.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00092.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00093.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00094.jpg)
then the coils and rats nest:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00096.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00097.jpg)
after that, the AC brackets, various pipework etc etc...
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00098.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00099.jpg)
Leaves me with a garage that looks like this!:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00100.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00101.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00102.jpg)
I also broke one of my OMP lines :( Does anyone know a good place to get an alternative? does anyone also know what this is? My 92 manual doesnt have this sensor...Its on the coolant neck
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day3/DSC00095.jpg)
Tomorrow i might crack on and tear the engine down completely, or clear up what i have right now. Depends how i feel to be honest!
P.s would you believe ALL of the above photos came off my camera phone? (just the last update) Its a sony ericson K800i. 3.2 mega pixel camera, its awesome!
Sweet. Pics are indeed damn good for a camera phone.
I think that sensor on the back of the filler neck is for the fans. Mine was an SOB to get off as well..
Looking good :wiggle
mine was just snapped full stop, i didnt break it!
Quote from: BobfishRocco - you will need a dial indicator gauge with magnetic base to check tolerances on the end plates, a set of micrometers of various sizes and some calipers to measure internal dimensions (wind the calipers out then measure the calipers with a micrometer)
Tolerance info is in the factory manual. There are various sheets on the web about it too.
Thank you Sir, your a gem! :D
No worries. Get your measuring tools from screwfix direct, nice and cheap.
Well got a few more bits done today. The good news is it doesnt look like im gonna have to spend any more money on parts!
My sophisticated flywheel locking tool:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day5/DSC00103.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day5/DSC00104.jpg)
Got everything off..
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day5/DSC00105.jpg)
Onto my oh so sophisticated engine stand she goes:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day5/DSC00106.jpg)
Alll the parts i removed:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day5/DSC00107.jpg)
Eccentric gear removed and tension bolts marked up:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day5/DSC00108.jpg)
First plate off:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day5/DSC00109.jpg)
Inside of housing looks good...if a little dirty.
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day5/DSC00110.jpg)
Rotors have quite a lot of carbon on them
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day5/DSC00111.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day5/DSC00112.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day5/DSC00113.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day5/DSC00114.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day5/DSC00115.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day5/DSC00116.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day5/DSC00118.jpg)
sweet....looks good mate....managed to get a set of housings and plates...gonna pick em up tommorow........
Well i thought i\'d better write an update as i haven\'t done one in a while now. TRuth be told i havent done a lot of work on the car! But i should be steaming ahead now, i have until the 6th of october now to finish this rebuild, remove the engine in my car, fix various leaks and re-fit it as im going to the nurburgring.
Ive removed the injectors and sent those off for cleaning:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day6/DSC00171.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day6/DSC00169.jpg)
Marked my rear rotor:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day6/DSC00167.jpg)
removed all seals etc:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day6/DSC00174.jpg)
got the front rotor fully cleaned:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day6/DSC00175.jpg)
and started work on the rear...
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day6/DSC00173.jpg)
This weekend will b espent cleaning that rotor, the end plates, various other componenets that need it and hopefully getting the engine built. I want to fit the engine one evening after work next week...
watch this space!
The temp switch on the front of the coolant housing is an additional switch for auto\'s only,to enable gearbox "lock-up" when the engine is warm. It reduces the work the gearbox does- reducing heat and wear.
Apparently.
Mines missing so am getting one fitted currently as sometimes the central tunnel scorches my left foot!
Bobfish i just wondered if you can give me some quick advise. (I tried to PM you but ut says you cant take PMs?).
I am soon looking at buying an RX7 and will be undertaking the task of rebuilding myself. I was just wondering where you get the parts from to rebuild, what is required, and how much it all costs!
Thanks very much.
email me, carl.newton@affiniti.com
ill reply to you tomorrow.
wow Mr fish thats fantastic!
Dont know how people go about doing something like this.
I cant change my headlights a the mo let alone rebuild the engine!
I look forward to the updates.
hey guys, sorry i havent posted in a while, been too busy working on the car!
heres the progress from the weekend and tonight...
Well heres the front rotor cleaned up..
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00175.jpg)
But look, disaster!!! A coolant seal broke...crappy mazda castings!!
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00176.jpg)
Luckily i had a spare on hand...so i got to work scraping out those grooves of 14 years worth of crap, and ended up with this...
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00179.jpg)
Time to measure it all up...
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00180.jpg)
Front plate:
No warping.
Side seal wear - 0.03mm, mazda spec <0.1mm
side seal overlapping oil seal wear - N/a, Mazda spec <0.01mm
Side seal outside oil seal wear - 0.02mm - Mazda spec <0.1mm
Oil seal wear - N/a - Mazda spec 0.02mm
Intermediate plate, front side
No warping.
Side seal wear - 0.04mm, mazda spec <0.1mm
side seal overlapping oil seal wear - N/a, Mazda spec <0.01mm
Side seal outside oil seal wear - 0.02mm - Mazda spec <0.1mm
Oil seal wear - N/a - Mazda spec 0.02mm
Intermediate plate, rear side
No warping.
Side seal wear - 0.03mm, mazda spec <0.1mm
side seal overlapping oil seal wear - N/a, Mazda spec <0.01mm
Side seal outside oil seal wear - 0.02mm - Mazda spec <0.1mm
Oil seal wear - N/a - Mazda spec 0.02mm
Rear plate
No warping.
Side seal wear - 0.02mm, mazda spec <0.1mm
side seal overlapping oil seal wear - N/a, Mazda spec <0.01mm
Side seal outside oil seal wear - 0.02mm - Mazda spec <0.1mm
Oil seal wear - N/a - Mazda spec 0.02mm
Eccentric shaft:
Front side outside shaft bearing external - 42.95mm
Front side outside eccentric gear bearing internal - 43.03mm
Clearance - 0.08mm - Mazda spec 0.06-0.11mm
Front side inside shaft bearing external - 42.97mm
Front side inside eccentric gear bearing internal - 43.03mm
Clearance - 0.06mm - Mazda spec 0.06-0.08mm
rear side outside shaft bearing external - 42.95mm
rear side outside eccentric gear bearing internal - 43.03mm
Clearance - 0.08mm - Mazda spec 0.06-0.11mm
Rear side inside shaft bearing external - 42.97mm
Rear side inside eccentric gear bearing internal - 43.03mm
Clearance - 0.06mm - Mazda spec 0.06-0.08mm
Then i dry assembled the rotors:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00181.jpg)
Ground my side seals...
front rotor gear side:
face1 0.25mm clearnace
face2 0.2mm clearance
face3 0.1mm clearance
Mazda spec 0.05-0.4mm
Front rotor open side:
face1 0.2mm clearnace
face2 0.1mm clearance
face3 0.15mm clearance
Mazda spec 0.05-0.4mm
Rear Rotor Gear side:
face1 0.1mm clearnace
face2 0.1mm clearance
face3 0.15mm clearance
Mazda spec 0.05-0.4mm
Rear toror Open side:
face1 0.2mm clearnace
face2 0.15mm clearance
face3 0.3mm clearance
Mazda spec 0.05-0.4mm
I put all my seals to one side on rotor build sheets...I made 4 of these, one for each side of the two rotors.
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00182.jpg)
Rotors now ready for wet assembly:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00184.jpg)
My engine build area! lol
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00185.jpg)
Off we go!
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00186.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00187.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00190.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00192.jpg)
And we\'re done!
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00193.jpg)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00194.jpg)
Flywheel on...
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00195.jpg)
Now to fit all this stuff :)
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day7/DSC00196.jpg)
Nice one Carl! I was gonna ask i I could drop round and watch...guess its too late for that :( Actually...i might need to do one thing tho...dyou mind if i drop round and identify label up my loom seeing as yours is correctly done!?
One of those flywheel locking tools is exactly what I need right now! I\'ve tried making my own but each attempt has ended in a twisted lenght of metal!
Mullins, for a flywheel loking tool get a length of angle iron from B&Q. It WONT bend, its solid stuff. for an auto drill on hole in the end and fix it with a bolt to the drive plate, then put a bolt through the next hole in the drive plate and just tighten it onto the drive plate with a nut like the photos.
For a manual, measure the distance from one bolt hole to the next little piece of dowel in the flywheel. Drill two holes this distance apart on the angle iron, and use one of the clutch retaining bolts to fix the angle iron to the flywheel and slide the other hole over the dowel.
I can give you the measurement if you dont have calipers.
One2Watch - no problems mate, see you tonight.
see photo, i actually used 2 bolts here but you can just slide it over the dowel. Obviously though 2 bolts is more secure.:
(http://i58.photobucket.com/albums/g268/delarado/Rex%20Rebuild/day8/DSC00008.jpg)
great work im going for this soon, just looking for the right car in japan, importing myself lol.. cn i ask how you cleaned all the engine parts? they look almost new at the end :)
Fantastic thread. Bobfish you and one2watch are brave guys for tackling a job of this scale. Makes me feel more confident about doing the same, hopefully not for a while though. And you\'re both local which I\'m sure will come in handy.
One question though, where did you send your injectors for cleaning? How long does it take and do you mind if i ask the cost?
Where did you get your flywheel puller from Bobfish?
Cleaned the engine parts with a brass brush, a screwdriver (for the coolant grooves) and standard engine degreaser solvent.
Injector cleaning i got done at Asnu - its local to me. Got the number from yellow pages. Takes a day and cost me 15 an injector.
Flywheel puller is a draper hub puller. make sure you use something larger than the ID of the shaft to protect your pilot bearing when pullnig though!
P.s NEW DISASTER
OMP line broke on removal. got a new one. wrong one! none of the others IN THE COUNTRY! gonna have to wait till next week. Have from the time i get the new OMP line till friday to finish the engine, reinstall in, remove my engine, fix the oil leak, fit a new rad and get a 4 wheel alignment. Maaan this is gonna be tight!!!
great thread fella,are you just using blue hylomar on the legs and vaseline on the waterseals to get keep them inplace?.
Also do you have the name of the engine degreaser as the one i have is crap,need to buy some better stuff
Blut hylomar on the legs and hylomar on the water seals also to keep them in place. It does a much better job than vaseline at it!
Engine degresear came in a big blue 5l can and is called "hyper clean"
Frankie. My injectors were sent down to reworx who do it for a tenner an injector. However, if id known about asnu, id prolly have taken it there as its definitely closer and from what Carl has said, they sound like they do a sound job.
Quote from: BobfishBlut hylomar on the legs and hylomar on the water seals also to keep them in place. It does a much better job than vaseline at it!
Have you had any problems with Oil leaks using Blue Hylomar on the legs???
I was told its too Thin and too use the Sump gasket sealer? (the Grey stuff)
Yeh Vaseline is just for moving parts like Apex\'s and side seals etc so the don\'t drop out.
Great thread.. keep it up!
Grizzly; short answer - no.
As you can see i put quite a thick coating on. I like to use hylomar because its a piece of **** to clean off!
the more i see threads like this the more i wanna rebuild a engine lol.. still looking for the right car then its all good.. :) just gutted ma garage and build a nice new workstation for the rebuild..YaY!
Quote from: BobfishGrizzly; short answer - no.
As you can see i put quite a thick coating on. I like to use hylomar because its a piece of **** to clean off!
But is\'nt Blue hylomar designed for use with a gasket? Where RTV isn\'t? I was told to check out the Grooves in the Legs (which was full of grey sealer) so i replaced mine with that.
But each to there own, if it does the job.
Just a quick update - the engine is fuly built and ready to go back in today. I picked up my alloy rad for my 7 today too. Hoipefully by tomorrow night i can have this car done, which leaves me until next friday to fit my rad, fix my oil leak and get a 4 wheel alignment on my car.
Went from this:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day8/DSC00199.jpg)
To this:
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day8/DSC00200.jpg)
And received this (thanks clive at Shy Auto! Your a star :))
(http://i58.photobucket.com/albums/g268/delarado/blackrxrebuild/day8/DSC00198.jpg)
should have it started tomorrow.
Quote from: Bobfishsee photo, i actually used 2 bolts here but you can just slide it over the dowel. Obviously though 2 bolts is more secure.:
(http://i58.photobucket.com/albums/g268/delarado/Rex%20Rebuild/day8/DSC00008.jpg)
Thanks mate. I got it off last night. I ended up using the hit it with a chisel method!:Nono!