My Engine Rebuild Thread!

[Jit]

Ive been talking about it for long enough, I thought it was about time I did something about removing my engine and rebuilding it starting today!
Some of you might have seen my "redoing the rats nest" thread. This would sort of follow on from that as I never actually put then engine back together again deciding instead to rebuild it.

Hopefuly this will provide an insight and some tips for other DIYers on how to cary out the rebuild and re-install the engine.

So couple of nights ago, I finally went and got myself an engine hoist! (well thats a lie...the truth is I went to see Steve (dubber91) and borrowed one off him! Cheers again matey )

And this morning, I put the Plenum back on the car and got the process going and removed the engine. To be honest, it wasnt anywhere near as hard as I thought it might be. At one point, I have having a few issues with the downpipe fouling on the steering arm. But I got around that by dropping the engine back into the bay off the mounts and jiggling the engine while a friend used a prybar to pull the downpipe clear of the turbos. I managed to remove the engine with the mounts still attached to the engine.

Other than that, the engine came out relatively easily. You may notice that unlike some, my loom is still in the car as it was easier to do this from where I was when working on the rats nest.

So heres a nice shot of the engine on the hoist coming out:

http://jitesh512.fotopic.net/p33293900.html

I made a couple of tiny errors here as I forgot I had removed two of the bolts on the engine hooks and both hooks as a result are slightly distorted from the weight. Remember to use loads of rags to stop any oil or coolant left in the block from spilling out onto your lovely paintwork!! I found that the bonnet didnt need to come off to remove the engine.

So next step, get the engine into the garage. As you can see, my garage isnt exactly big! And I had to buy a desk to carry the rebuild out with...luckily I found that white desk on ebay for £1 right next to my girlfriends house!

http://jitesh512.fotopic.net/p33293897.html
http://jitesh512.fotopic.net/p33293895.html

Anyhow, I was quite pleased that the engine came out nice and easily so decided Id have a got at trying to get the engine down to the bare block after lunch! And within a few hours, Id removed this lot in the following order:

Second Turbo Inlet Pipe, Plenum, Both Injector Rails, Y-pipe, Turbo pack, Turbo Manifold, Engine Mounts, Lower Intake Manifold, Water Pump Pulley, Water Pump.  And here we are on my £1 desk lol!

http://jitesh512.fotopic.net/p33293899.html

And this is what my engine now looks like! Quite a contrast to a few hours earlier!

http://jitesh512.fotopic.net/p33293896.html



Tommorow, my aim is to remove the rest of the bits left on (Oil filter base and Oil lines, Oil Injectors, Injector Diffusers, Crank Pulley and possibly the sump but only if my girlfriend can spare me her cat litter!) Hopefully I can add some more piccies tommorow of the work. Its a shame Im working at the moment so Ill hopefully be able to start the strip down of the block next weekend!

[Mr_7]

nice one jit looking good glad to hear you finally decieded to crack on it. have the dvds come in useful yet lol?

[Jit]

Not yet....hopefully weekend after next I reckon! Sorry to hear bout your running probs

[nikp]

It\'s definately worth doing - I\'m having a few teething troubles, but nothing major. And it starts sooooo easily when hot now. It\'s looking very good on my front. Done 20 miles now!

[Bobfish]

Things will get better Nikp. I did my own rebuild, still going strong 5k later!

[Jit]

Right following on from yesterday, I havent really got anywhere near as much as I wanted done :3Confused

Started off by removing the oil filter base (2 10mm nuts), Oil injectors and what I think is the oil metering pump (from the front cover - 3 10mm bolts), the coolant temp sensor (12mm deep socket), oil pressure switch, Crank Angle Sensors (2 10mm bolts) and the two remaining spark plugs.

Next step was to remove the sump (17 10mm bolts). I was surprised at just how much oil was still left in the sump even though i had drained it! :3Confused Sump was held on with plenty of sealant so needed to use a plastic mallett and a filler knife to remove it carefully.

Next step was to remove the oil strainer from the block (2 10mm bolts) and the oil pressure regulator and spring and piston. I should really have a snapped a pic but it basically looks like a large bot that sort of sticks off th sump mating surface. I used an adjustable  wrench to undo it...the spring should come out with the nut and youll need a telescopic pick up magnet to grab the piston from its bore.

Had a whirl at trying to crack the crank pulley until i looked up what torque its done up to lol!! I think ill be buying a slightly bigger breaker bar and a proper flywheel stopper!!! And an engine stand lol!!
So far so good though...heres what my engine looked like when id done all the above:

http://jitesh512.fotopic.net/p33326790.html
http://jitesh512.fotopic.net/p33326791.html

[Ricco_04]

Top stuff :Thumbs-up  - another thread im following with interest!

[Bobfish]

The way i did my front eccentric shaft nut and flywheel nut was i got a transit wheel hub socket, and i think a 19mm impact socket (for front nut)

I used them both on a 3 foot breaker bar, with another 3 foot scaffold pole slid over it to help leverage. To stop the flywheel i used a 5 foot piece of angle iron with holes drilled in it - one hole slid over the dowel sticking from the flywheel while the other was screwed into the flywheel itself. Using this bar, my 6 foot breaker bar and 2 fat friends to stand on the engine i managed to break them both off. Bouncing on the bar is a good idea, youll never get it off just pulling it.


Good luck!

[Jit]

and you know how small i am!!! We managed to get one off Steves (dubber91) TII engine between the 2 of us so ill prob try and enlist his help!!

[probedb]

Nice one Make sure you have a 54mm socket btw as you\'ll need it! I\'ll be doing mine in a couple of months hopefully so I\'ll be watching your progress with interest.

[Jit]

Right an Update. Bit of a long post this one, so you might want to get a cup of tea or something lol :guinness ! Would have updated on the weekend but didn’t really get all that much done on the weekend! All I managed to do was loosen off the Front Eccentric Shaft Bolt and also the Flywheel Nut. I got stuck somewhat on Sunday as I was unable to get the flywheel off the shaft. I didn’t want to hit it too hard otherwise I may have squashed the pilot bearing. To hold the flywheel locked while removing the nut, I used a tool that was sent to me by Ian Elvar (cheers again mate lol! :Ladys-man ).

http://jitesh512.fotopic.net/p33747354.html

Anyhow, Carl (Bobfish) came round yesterday and helped me remove the flywheel (cheers again mate…ill drop that tool round in the morning once I got the van power steering working!).

All of this meant that today I could crack on with dissembly of the main engine block… which I duly did! Time to find out exactly what re:worx put into my engine! :flamed

First thing to do today was to remove the Front Cover. This was a relatively simple case of 7 or 8 bolts. With the cover off, the next thing done was to check the oil pump drive chain slack. I measured the slack in mine to be ¼ inch which is within specification.

http://jitesh512.fotopic.net/p33747353.html
http://jitesh512.fotopic.net/p33748667.html

With this done, next job was to remove the Oil pump chain assembly along with the accessory gear.

http://jitesh512.fotopic.net/p33748668.html
http://jitesh512.fotopic.net/p33748670.html

With that off, next the attention was turned to remove the front counterweight, front washer, front thrust bearing and front key. These just slid off the shaft.

http://jitesh512.fotopic.net/p33748671.html

Next came the 6 front stationary gear bolts. After undoing these, I removed the centre plate and the spacer (the spacer is used to set the end play upon re-assembly) and the rear bearing and washer. The spacer removed was noted to be a “c” spacer.

http://jitesh512.fotopic.net/p33748669.html
http://jitesh512.fotopic.net/p33748672.html
http://jitesh512.fotopic.net/p33761474.html

So up until this point, we have removed the following components. From top to bottom in this picture ( http://jitesh512.fotopic.net/p33761475.html ), we have:

1. Oil Pump Chain and accessory gear assembly
2. Front Washer
3. Front Counterweight with key sticking out.
4. Front Engine Thrust Bearing
5. Stationary Gear bolts (only 5 shown in that picture as one was put back in to hold the front stationary gear in place during dissembly)
6. Centre Plate
7. Spacer
8. Rear Engine Thrust Bearing
9. Rear Washer

After this, the next step was to remove the Oil pump held on by 4 bolts.

http://jitesh512.fotopic.net/p33761473.html

After this came the main dissembly of the engine block….once my photos have uploaded onto fotopic, ill finish the write up. :guinness

[Jit]

Right, now that the photos have loaded, Ill carry on! This bit is the main block dissembly. First thing I done was to tape up the eccentric shaft threads to protect the threads and the bearings (according to the dvd I was following).

http://jitesh512.fotopic.net/p33764083.html

First I removed the Flywheel key and then I removed the six retaining bolts for the rear stationary gear and used a trim tool to pry the gear away from the rear end plate. So the assembly pile now looks like this:

http://jitesh512.fotopic.net/p33764081.html

And the rear end plate looks like this!:

http://jitesh512.fotopic.net/p33764086.html

I then followed the Haynes Manual Guidance on the order for loosening off the tension bolts. Just to be on the safe side, I cracked them all half a turn first in sequence. I then went and done them all another half turn and finally removed them. I think that was a bit excessive but rather that than warp any components. The number 2 tension bolt is slightly longer than the rest.
So we now have a rear housing that looks like:

http://jitesh512.fotopic.net/p33764082.html

And a Components layout looking like this:

http://jitesh512.fotopic.net/p33764085.html

So I now removed the end plate. I was expecting to have to tap it with a deadblow…hell I even bought one in preparation (guess itll have to go back then lol!)…as it transpired, I didn’t need it as the whole assembly seemed to come apart as soon as id loosened off the tension bolts! Im not really sure if this is normal.

So here we have the Rear End Plate removed:

http://jitesh512.fotopic.net/p33768924.html

Looking inside the housing, we can see the rear rotor.

http://jitesh512.fotopic.net/p33768927.html

Next step was to remove the rear rotor and then the Intermediate Plate. This was done by pushing the E-Shaft rearwards (from the front) and rocking the Intermediate plate over the Shaft Lobe.

http://jitesh512.fotopic.net/p33768928.html

Finally, I removed the Front Housing, Eccentric Shaft and Front Rotor (in that order). That concluded the dissembly of the engine.

http://jitesh512.fotopic.net/p33768926.html
http://jitesh512.fotopic.net/p33768923.html

The plan for tomorrow is to start cleaning all the parts….well maybe ill buy some parts cleaner first lol…. :Hammer

[MillSpeed]

Awesome write-up! Keep it coming.

[Bobfish]

Looks good Jit, good to see your cracking on with it! Those end plates definately look ported, but i suspect (by the looks of them) those housings were re-used at rebuild. How many miles did it do after the rebuild? you shouldnt get a finish like that on the rotor housings until after about 20-25k at least.

[Bobfish]

P.s i have all the measuring gear if you want to check your end plates and bearings (calipers, micrometers, dial indicator on a magnetic base etc) give me a shout if you want me to come up and show you how to do it/borrow them.

Did you still want to take me up on the offer for those end plates mate? Email me at work about it if you like

Carl