I'll give it a blast on Friday, thanks!

________________________________________

Get used to seeing the yellow one !!!
Team 330™
Team "no front end or engine"
Team "LIMITED EDITION" I live for the 306 sticker
Team 0-60 in 6.44 & standing qtr in 14.808 @ 94.55mph all with std engine
203bhp Corolla T-Sport daily driver stealthier than Kwai Chang Caine

Update time....
Well..... I took the pistons out, what a good tip to unscrew each bolt 4 turns & give them a tap with a light mallet, it worked a treat splitting the end caps from the rods.
I checked each ring in it's bore & guess what
The ring gap on every top ring was 0.30mm


The ring gap on every second ring was 0.35mm


And all the scraper rings were 0.20mm

I decided to leave them all alone, my theory was that with it having freshly bored & honed bores the gaps should grow as everything beds in.

I reassembled the pistons into the block (again)


& I used the correct ARP lube on the bolts, on the threads & under the heads.


I then torqued all the bolts 45 foot lbs, loosened them off & torqued them to 45 foot lbs again.
I then fitted the splash tray.


Then I dug out the spacer plate that goes under the oil pump, easy to forget I guess..


Most people know that I'm a bit of a horder, a couple of years ago Richw had an oil pump for sale that had just been refurbished by Richard Longmans, so as normal I snapped it up in double quick time.
Here it is fitted.




Next I put some beads of Locktite RTV gasket compound onto the face of the sump & fitted it onto the block.



What I'm after now are the 4 alloy top hat bushes that fit onto the sump so that I can mount the power steering pump relocation brackets.


Virtually completed bottom end.


Thought I'd make a start on reassembling the head.
First job was to fit the valve stem oil seals.


No matter what I tried I just couldn't apply enough pressure with my fingers down the sharp follower bores then I found the perfect size imperial socket.



All I had to do was put the socket on the long extention, line things up & give each one a smack or two with a bfh.

All 16 valve stem oil seals fitted in 5 minutes


Twin springs in place.


Now when I put the caps on & put the valve spring compressor on it took me about an hour to fit the first pair of collets, even using magnetic screwdrivers & grease.
I eventually got the knack & the other 7 inlets went together a dream.


By the time all the inlets were in it was 6.45pm & I had to be home by 7 so I shot off home, the exhausts will have to wait till next weekend.

If anyone has some spare alloy top hat spacers to enable me to fit the power steering relocation bracket onto my sump please drop me a PM, I've had enough of being raped by my local main dealer!!!

Cheers

________________________________________

Get used to seeing the yellow one !!!
Team 330™
Team "no front end or engine"
Team "LIMITED EDITION" I live for the 306 sticker
Team 0-60 in 6.44 & standing qtr in 14.808 @ 94.55mph all with std engine
203bhp Corolla T-Sport daily driver stealthier than Kwai Chang Caine

Yes you do ! Leave the bloody jetski alone its pretty much winter FFS!!

Better late than never, my guestimate wasn't too far off so I'm a happy chappy!

Hello Mr Platt,


Recommended ringendgap on the top ring is 0,35 to 0,4 and 0,35 to 0,60mm on the second ring.

These figures vary a lot because they depend on so many surrounding specs. The final decision is always with the engine-builder.


Best regards,

Antonio Pirocco

Wössner GmbH

________________________________________

Get used to seeing the yellow one !!!
Team 330™
Team "no front end or engine"
Team "LIMITED EDITION" I live for the 306 sticker
Team 0-60 in 6.44 & standing qtr in 14.808 @ 94.55mph all with std engine
203bhp Corolla T-Sport daily driver stealthier than Kwai Chang Caine

I take it you got the pullies alright mate?

________________________________________

Contact Details:

rich@lynxpowerengineering.co.uk
07732 822546

The main stealer let me down with the bloody camshaft oil seals, he now says they will be here on Tuesday!
I want to Halfrauds yesterday & bought a ½" drive T55 torx drive to torque the head up, while there I also got a ½" to 3/8 & a 3/8 to ¼ adaptors.
When I came to start torqueing the head bolts the new torx drive was too big a diameter to fit into the head & locate in the head bolts, FFS!!!!!
Bloody good job I got the adaptors! I managed to use the 3/8" drive T55 out of my socket set with the ½" to 3/8" adaptor. Although I was worried the adaptor would shear off all worked out fine.
The torque settings I used were
Stage 1 35nm
Stage 2 70nm
Stage 3 +160 degrees

I was sweating my nads off by the time I finished, it's certainly hard work putting the 160 degrees on with the engine on the engine stand with wheels on the bottom!!!

I then got stuck into cleaning up the thermostat housing with a wire brush..


I may have got carried away with the RTV sealant but if this bugger leaks I'll show my arse on the town hall steps!


Once it sets I'll trim the excess off!

When I was taking the engine out I couldn't get the o/s drive shaft out of the support on the back of the block so I split the drive shaft & cable tied a rubber glove over the end to keep the shit out.
Over the last few weeks I've been spraying plenty of WD40 on the bearing in the support. Surprisingly there is nowhere really on the support where you can hold it in a vice so I gripped the rubber engine mount bush & holding the driveshaft pushed it up until things went solid & then hit the splined end of the shaft with a bfh, I was quite gentle at first but it didn't take long before I was properly smacking it. After about 5 mins of gentle persuasion it started to move slightly, 3 more "taps" & it was out.
One of the few things I haven't got it a press, so to get the bottom bush out I put a hacksaw blade through one of the voids & cut the middle out, I then carefully cut through the outer steel band & knocked it out with a pin punch.
I then set about cleaning all the crud & oil off the support. The parts washer came into it's own with a toothbrush & then a wire brush. I then realised what a p*ss poor casting it was with flash all over the place, me being me I set to with the file & tidied it up.
Next was to try & fit the Baker BM bush, no press remember so I gave it a "little tap" with the BFH to get it started & then I started squeezing it either side in the vice trying to keep it square a mm at a time, then when about half way in it started to keep itself square & with the help of a 4 foot long piece of pipe on the vice handle it slid in nicely. I then bolted the support onto the block.

Back to the garage tomorrow.

Edit, spent Sunday in the garage then had to take youngest daughter to hospital, she's been admitted, I was there till 4am, update on car to follow tonight when I get chance.

________________________________________

Get used to seeing the yellow one !!!
Team 330™
Team "no front end or engine"
Team "LIMITED EDITION" I live for the 306 sticker
Team 0-60 in 6.44 & standing qtr in 14.808 @ 94.55mph all with std engine
203bhp Corolla T-Sport daily driver stealthier than Kwai Chang Caine

Sunday update...
I decided that I don't want to bolt any manky looking ancillaries onto my shiney new engine, thought I'd start with this p*ss poor example of an alternator.



I started by taking the plastic cover off the end.


First I removed the 2 screws to remove the brushes, the cream coloured bit.
I then removed the other 3 screws.
Then I removed the 4 bolts that hold the two halves of the alloy casing together.
Would it come apart?
No!!!!
I started looking more closely & I spotted 3 small screws under the pulley, so off came the pulley & after a lot of messing about I managed to get the screws out.
Would it come apart?
No!!!!
FFS!!!!!!!!!!!!!!
For the life of me I just couldn't find what was still holding it together, 10 cigs later I decided to bin the idea of getting the alloy casing sand blasted, wire brushing will just have to do!!!!
I cleaned up all the bits the best I could & reassembled it all.

I then started work on the power steering pump, first job was to rotate th fluid input elbow so that it points upwards when mounted on the new bracket.
I held the pump in the vice, got a long series socket (big enough to fit over the pipe) with an extention fitted to give me enough leverage & I started to put more & more weight on it until it started to move. The trouble was it wasn't actually moving it was bending! Bugger!!!!
5 cigs later I decided to dig out a heat gun normally used for stripping paint off skirting boards & I started to apply heat to the pump around where the elbow is (not directly on the elbow) until slight smoke started to come out of the pipe. This time when I started to apply pressure there was a crack & it started to move, 10 seconds later it was rotated to the correct angle.
Tadah!!

I then set to with the wire brush to clean it up.

Next came the vacuum pump, this was far simpler & just needed a good going over with the wire brush.

I just couldn't resist carrying on with the under bonnet theme, here they are fully tarted up...


Next on the agenda was the throttle body.




Shit up was an understatement!
I stripped everything off it I could & chucked it in the parts washer.


Looking at it the casting is too intricate to clean up with the wire brush, has anyone ever removed the 2 screws that hold the butterfly in place to get the throttle spindle out?
I think I need to remove them so that I can get it sand blasted...

At this point I got a phone call from the wife telling me I had to get to the hospital, my youngest daughter (20) has bad tonsillitis, think it's actually called Quincey

More next weekend!

________________________________________

Get used to seeing the yellow one !!!
Team 330™
Team "no front end or engine"
Team "LIMITED EDITION" I live for the 306 sticker
Team 0-60 in 6.44 & standing qtr in 14.808 @ 94.55mph all with std engine
203bhp Corolla T-Sport daily driver stealthier than Kwai Chang Caine

Yeh it looks like the threaded ends have been peened over where they poke through the other side of the spindle, I may just have to tape it up before it's blasted

________________________________________

Get used to seeing the yellow one !!!
Team 330™
Team "no front end or engine"
Team "LIMITED EDITION" I live for the 306 sticker
Team 0-60 in 6.44 & standing qtr in 14.808 @ 94.55mph all with std engine
203bhp Corolla T-Sport daily driver stealthier than Kwai Chang Caine

Ohhh don't worry, it will be getting the wire brush treatment!

________________________________________

Get used to seeing the yellow one !!!
Team 330™
Team "no front end or engine"
Team "LIMITED EDITION" I live for the 306 sticker
Team 0-60 in 6.44 & standing qtr in 14.808 @ 94.55mph all with std engine
203bhp Corolla T-Sport daily driver stealthier than Kwai Chang Caine

i've just decided my engine bay isn't clean enough now damn you!

I need an ultrasonic cleaner, think my dad has an old one at home for cleaning jewellery

________________________________________

Bye bye Sundance Kid

Cheers lads, don't worry over the rtv sealer, I put the beads near the outside edge. Funny thing is that I must have spent hours scraping the old rtv off, I can't ever see it coming lose on it's own....

Anyhoo, Santa has been today!
From the mainstealer I got...
2 x camshaft oil seals part No 023644 £9.31 each + vat


Next the bushes required on a Rallye sump to relocate the power steering pump.


2 x part number 06453AR (alloy) £1.15 each + vat
2 x part number 06453CJ (steel) £1.51 each + vat


And a package arrived from Motorsport Tools
A 350mm 75mm dished steering wheel, really nice quality feel for just over £50


Two pulls, one for electric cutoff & one for extinguisher.


Two CDS tube seat mounting kits.


And finally a sheet of real carbon fibre with 3M selfadhesive on the back, I'm buggered if I'm going to pay £65 for 2 carbon vent covers off eBay! It will also come in handy for where my feet will catch the door bars & if I'm really lucky I'll be able to cover the top glovebox, it was just over £20 for a sheet, bargain!!!


I've also been doing a bit of research into snap off steering wheel bosses.
For motorsport use you must have a weld on boss that is spline located & is released by a circular YELLOW ring that must be behind the boss, that you pull towards you along the axis of the steering column to release the wheel. That counts out all but a handful of the bosses available on eBay. Looks like I'll have to save up another £130 odd quid for that then

________________________________________

Get used to seeing the yellow one !!!
Team 330™
Team "no front end or engine"
Team "LIMITED EDITION" I live for the 306 sticker
Team 0-60 in 6.44 & standing qtr in 14.808 @ 94.55mph all with std engine
203bhp Corolla T-Sport daily driver stealthier than Kwai Chang Caine