Yet another rebuild thread!

[Icesurf3r]

Hi Dan

Spoke to Matt and Tim, it\'s up and running, they\'re just finishing off some little niggle jobs i needed doing. but they\'re plowing deeper into my pockets lol, as been told i now need a new radiator and 2 new front tyres.... (Now where did i put my spare kidney??) At least i know they\'re doin a grand job, and shall be praising them highly when i get her back ....

But still on for thurs

[dandan]

excellent news, i have a spare stock sized rad... i think it survived the accident, prob no good for you though, not big enough.

Well looking forward to my day off on thurs!

[daverey]

Dan
 may have an hour or so wednesday evening will call if I have. Would like to see new car.
 Dave

[dandan]

Quick little update,
I have started the long slow cleaning process, a lot of things will just be getting a good scrub, but there will be a bit of paint needed and possibly some elbow grease, anyone know where I can get a nice big tub of that from?

First thing that came to hand was the radiator, so i just cleaned it down, picked out the bits of dead bug etc, and cleaned a bit of corrosion off the fan housings.
Here are the rad mounts, now i know it\'s not an important part of the engine bay but hopefully if I can start as I mean to go on it should look good in the end.
Before:


And After:


much better!
Fingers crossed everything else will be as easy to clean!

[dandan]

ooooh look what i got back several weeks ahead of schedule...



Thanks to re:worx and whoever their turbo specialist is for getting it sorted so quick, I wasnt expecting it to come back looking quite so shiny!

[dandan]

One Word:  Autosol

Three Words: Bloody good stuff

A Few More Words: after buying a job lot of elbow grease(tm) off ebay, I got to polishing some of the shiny bits on the engine, they had been previously polished (with the exception of the alternator) but had been left to tarnish for a long time and were in a pretty sorry state so I picked up some highly recommended Autosol metal polish and got cracking.




Pretty good i reckon, the turbo could do with another hour of attention really, but I want to get the engine in so it will have to wait. still got to do the plenum but I did a test piece of it and it is going to sparkle!

On the mechanics side of things, I got the sump back on, filler neck and water pump back on the block, lower intake manifold, secondary rail, primaries, fuel and oil lines, etcetc back on, oil filler on, and coil pack on.

The sump required some elbow grease to get the old sealant off (good thing I bought a big tub), but when I had both contact surfaces looking cleaner than the popes forehead I covered them in Mazda sump sealent and bolted it all back together. (not forgetting to put the oil pickup filter/tube thing in first)

A new o-ring went into the thermostat and a gasket in the connection between filler and block, with a bit of Hylomar to be safe, as the filler was covered in limescale-y stuff which looked like the whole thing wasn\'t very water tight last time it was put together.

When Davehg came and helped me pull the engine out, he left the injectors, rail, fuel lines, oil lines, remainder of rats nest, loom etc all connected to the lower intake manifold and pulled the whole thing off in one. It was a bit awkward jiggling it all back into place myself but I managed it eventually, plugged in everything that looked like it should be plugged in, and bolted it all down. There are still a few open connections but some of them will go to other ancillaries which are yet to go on.
The whole thing will be checked over by an expert before I put it back in anyway, just to be safe.

Then I just slapped the coil packs back on top (i had mis-labelled two of the HT leads, good thing they only reach to certain spark plugs!)

I didn\'t get a picture of how it looks now, but it is certainly taking shape, and thus far nothing has got me completely stumped, which is a minor miracle!

[Gord.R]

OOOO Very shiny dan...looks great... so should be up and running by the end of the weekend then ... wish my rebuild was a quick!!

Cheers

Gord

[dandan]

ah you may jest gord, but i fully intend to turn the key before the sun sets on monday!
Barring any major disasters this shouldn\'t be a difficult timeframe i\'ve got four solid free days to do it, everything is ready, it just needs to be put in place. Not looking forward to locating the block onto the bell housing on my own but i\'ll give it my best shot! everybody wish me luck please.

[Warthog]

Good luck mate --- nice job. :cool

[Gord.R]

LOL...Dan ok ok ill believe ya!!

OO have fun...i took it out on my own..would have been eaiser if the old man actually made an effort to help!!! :2Mad  :spank

Good Luck mate...expect a  vid of it running on monday!! PROOF!

Ta

Gord

[FD3UK]

Good work Dan. No mention of what failed internally, what did you end up replacing?


Kev

[dandan]

Hi kev, right I dont want to curse it but when we had everything out, geff looked over then engine and reckoned there were no immediate signs of oil seal failure to cause the white smoke, so I decided not to break the block apart immediately. The turbo then got sent off to be looked at and it was found to need the oil seals replacing, so i\'m hoping against hope that the turbo was the cause of the white smoke, and I don\'t need to rebuild the block at all!
I suppose i\'ll find out when i turn the key...

[Bobfish]

Id say if the engines got more than 50k on it rebuild it anyway.

[dandan]

no worries on that front bobfish, the engine is less than 10k out of a rebuild from WGT so I\'m hoping everything should be good. Both tim (rxmotors) and geff (RE:worx) have commented on it having great compression just from turning the flywheel by hand.

its going in today so wish me luck!

[robedwards99]

Good luck Dan!