Liam's race car project

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Liam22
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Re: Liam's race car project

Post by Liam22 » Sun Aug 12, 2018 11:25 pm

A good engine with a fresh(ish) rebuild and streetport turned up (thanks Juey) so I decided go for that and replace my engine even though diagnosis is incomplete.

Tempting as it is to upgrade the engine and run in class B (240bhp/ton) it would mean shooting for 280bhp at the flywheel which I don't think is realistic. And the fuel consumption is bad enough as it is!

So the streetport should see me at about 220bhp which keeps me right at the top of class C (180bhp/ton). Currently considering my options for mapping the ECU to get the most out of it.

Picked up the engine from Pete at Boston Rotary on Friday.
Image

Borrowed an engine hoist and set about removing the old engine over the weekend. Drained the fluids and removed my good, non-rusty sump yesterday.

Today I did the hard work and got the old engine out. Spent too long fighting with stubborn coolant hoses. But worse was every electrical connector and every bolt came out dripping with oil which slowed me down as I cleaned up along the way.

The ECU security bolts were another unpleasant surpirse. Pilot hole and screw extractor on an impact wrench mostly worked, but some needed drilling out.
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More of a shock was the state of my offside engine mount. The rubber around the top mounting bolt has almost completely sheared off. Scary!
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After mucho swearing at bell housing bolts and breaking my breaker bar [sic] the engine is now out.
Image

It's going to take a good while to remove various parts from old engine and prepare the new one.
Image

Swap clutch and flywheel
Swap D585 coils
Swap exhaust manifold
Swap Sohn and OMP
Swap sump (prob after it goes back in the car)
Remove A/C pulleys and bracketry
Blank off heater outlet and inlet (seems like a good opportunity to remove the heater hoses)
Delete throttle body coolant plumbing
Delete VFAD and air pump vacuum hoses
Clean up a bunch of rust
And everything else I've forgotten

My biggest concern right now is how to remove the flywheel nut. I think I'll need to buy or borrow a full fat nut busting impact wrench. Any models known to do the job would be much appreciated.

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Re: Liam's race car project

Post by warpc0il » Mon Aug 13, 2018 12:17 am

Just don't do what a mate of mine did with his Escort many years ago...

- Got a good used engine to replace his sick lump.
- Pulled his old engine and did a mix-n-match of the best of the ancillaries, sump, rocker box etc
- painted the block
- put engine into car
- found that "new engine" was no better than old engine :( :?

Asked me to give him a hand the next weekend
- after a lot of head scratching I worked-out that he'd put the old engine back in the car and the "new engine" was outside in the rain, with all the left-over bits #-o
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Re: Liam's race car project

Post by boosted » Mon Aug 13, 2018 12:39 am

Diy at home flywheel removal...chain bolted on flywheel 1 of clutch holes and 1 on engine.
Lump hammer and chisel...good hard whack on the nut...i got a socket an impact gun just wouldnt budge...plenty of nuts on ebay.
Once nut off flywheel may not slide off again give it a whack and resonance should loosen it from shaft.

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Re: Liam's race car project

Post by untakenname » Mon Aug 13, 2018 1:56 am

Decent (500nm+) impact drivers will remove the nut, otherwise it's just brute strength and a lot of leverage.

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Re: Liam's race car project

Post by Liam22 » Thu Aug 16, 2018 10:33 am

Flywheel nut sorted with one of these:

http://www.makitauk.com/products/cordle ... rench.html

Of course, the bigger problem is removing the flywheel itself!

Started moving bits across to the new engine. Gonna have to figure out a better way of deleting the throttle body and heater hoses.

Also, I have an irrational hatred of the alternator tensioner bracket and decided to swiss cheese it. Only 40g lighter... But I felt better :)

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Re: Liam's race car project

Post by zippyonline » Thu Aug 16, 2018 11:14 am

Liam22 wrote:
Thu Aug 16, 2018 10:33 am
Flywheel nut sorted with one of these:
http://www.makitauk.com/products/cordle ... rench.html
I've got one of those - it's fricking awesome! :D

Nice to see progress coming along after Spa Liam, best of luck. :)
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Re: Liam's race car project

Post by 13Black » Thu Aug 16, 2018 11:20 am

A good few hard batterings with a rubber mallet on the face will shift the flywheel, never fails.

I've seen engine mounts do that as well, weird!
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Re: Liam's race car project

Post by qwakers » Thu Aug 16, 2018 9:07 pm

Liam22 wrote:
Thu Aug 16, 2018 10:33 am
Flywheel nut sorted with one of these:

http://www.makitauk.com/products/cordle ... rench.html

Of course, the bigger problem is removing the flywheel itself!

Started moving bits across to the new engine. Gonna have to figure out a better way of deleting the throttle body and heater hoses.

Also, I have an irrational hatred of the alternator tensioner bracket and decided to swiss cheese it. Only 40g lighter... But I felt better :)

Image

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makita, good choice :D and only the baby one like mine too.... my dad has its big brother. makes the little one look silly.

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Re: Liam's race car project

Post by Liam22 » Thu Aug 16, 2018 10:06 pm

There's a *bigger* one?! I thought 3/4" square drive was good going. Did both flywheel nuts on position 2 (of 3).

New pair of engine mounts arrived today. Gonna try a harder polyurethane compound this time and drill a bit deeper to stop the rubber top from moving.

Just need to swap the Sohn adapter, do a better heater bypass, and I can get the new engine in thr car.

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Re: Liam's race car project

Post by Liam22 » Mon Aug 20, 2018 12:11 am

I was all set to get the new engine in the car when I took a closer look at the clutch and noticed that there isn't a lot of friction material left. I've ordered a new 6 puck friction plate which should work just fine with my Comp Clutch cover.

I also noticed when swapping the spark plugs that L2 is missing its side electrode! Either its fallen off or something inside the housing has decapitated it. New plugs also on order.

Thankfully I'm in the US next week so will save a lot of cash. Even with the weak pound the plugs are half the cost.

So to make progress I filled the new engine mounts with polyurethane. I deliberated drilled right through the rubber in 4 places to create plastic dowels when the polyurethane sets in an attempt to stop the rubber part from moving.

Image

This time I selected a harder compound, D70-75, which is in the full rigid plastic range. Gets very hot when setting!

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Re: Liam's race car project

Post by Liam22 » Thu Aug 23, 2018 4:05 pm

Total cost £114 :)

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Re: Liam's race car project

Post by Juey » Fri Aug 24, 2018 11:27 am

...can't wait to see it fire back into life.
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Re: Liam's race car project

Post by Liam22 » Sun Aug 26, 2018 7:59 pm

Juey wrote:...can't wait to see it fire back into life.
Still some way to go.

This was the L2 plug from my old engine. Where'd the tip go?!

Image

New clutch disc is now on so hopefully I can at least get the new engine in the car tomorrow.

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Re: Liam's race car project

Post by boosted » Sun Aug 26, 2018 8:00 pm

Did the tip have a meeting with the sideseal?

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Re: Liam's race car project

Post by Liam22 » Sun Aug 26, 2018 8:04 pm

boosted wrote:Did the tip have a meeting with the sideseal?

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That's the current theory.

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Re: Liam's race car project

Post by boosted » Sun Aug 26, 2018 8:08 pm

Mine been in a while (3 engines)...mmmm think ill change...

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Re: Liam's race car project

Post by Neilparry » Sun Aug 26, 2018 10:52 pm

Quick everybody
Remove your plugs to check 🧐

Seriously it seems a good idea to change them if they got some miles on them. better safe than sorry



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Re: Liam's race car project

Post by Liam22 » Mon Aug 27, 2018 7:53 pm

Added a little protection to the OMP wiring to protect from stones and debris.

Image

Final cleanup of oil from the engine bay, and the appropriate lubrication to gearbox input shaft. All ready to accept the new engine.

Image

Very slowly edged the new engine into place. It's bloody tight! A helping pair of hands from my wife helped tremendously. Don't think I could do it solo. It's not all the way on. Needs repositioning on the hoist to allow pushing further aft. Currently resting on blocks of wood.

Will get it pushed home in the next few days.

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Re: Liam's race car project

Post by Liam22 » Thu Aug 30, 2018 12:17 am

Just spent 3 hours trying to pull the engine onto the gearbox. (now done)

I am sh*t at spannering sometimes.

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Re: Liam's race car project

Post by mrspiller » Thu Aug 30, 2018 7:37 am

Liam22 wrote:Just spent 3 hours trying to pull the engine onto the gearbox. (now done)

I am sh*t at spannering sometimes.

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Nice evenings work then .....


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Re: Liam's race car project

Post by qwakers » Thu Aug 30, 2018 7:40 am

Liam22 wrote:
Thu Aug 30, 2018 12:17 am
Just spent 3 hours trying to pull the engine onto the gearbox. (now done)

I am sh*t at spannering sometimes.

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dont feel bad, thats a total pita on your own. infact when working on mr2s back in the day, id pull the gbox and engine out as a unit if i had to split them, it was easier.

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Re: Liam's race car project

Post by warpc0il » Thu Aug 30, 2018 9:10 am

Liam22 wrote:
Mon Aug 27, 2018 7:53 pm
Added a little protection ... and the appropriate lubrication to the shaft.

Very slowly edged into place. It's bloody tight! A helping pair of hands from my wife helped tremendously. Don't think I could do it solo. It's not all the way on. Needs repositioning on the hoist to allow pushing further aft. Currently resting on blocks of wood.

Will get it pushed home in the next few days.
I can relate to that :twisted:
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Re: Liam's race car project

Post by Liam22 » Sat Sep 01, 2018 8:11 pm

New engine is now in and sitting back on its engine mounts. Not much left to do apart from replace the sump and baffle plate.

Decided to simplify the D585 mounting and ditch the OEM bracket. Double bracketry makes me sad.

Without the aircon compressor fitted there's enough room to mount it vertically, and using the existing holes.

Test fitted on the old engine. Will get it on the car tomorrow.ImageImage

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Re: Liam's race car project

Post by mrspiller » Sat Sep 01, 2018 8:26 pm

Good idea


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Re: Liam's race car project

Post by warpc0il » Sat Sep 01, 2018 9:44 pm

That should help keep the coils cooler
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