Rebuild Progress
 

Hey...it's been a few months since I've posted on here. I ended up needing to have the block bored out, ended up going to OS2 pistons, and finally got the block back from the shop just last weekend. Spent most of last week painting everything in my house...coffee tables are perfect for painting a block i've learned! So did pretty much everything using POR15 engine enamal.

Before
Attachment 23662

After Paint
Attachment 23663

Attachment 23664

Attachment 23665

Attachment 23666


So this weekend is time to make some progress actually putting stuff backtogether for a change... It's taken waaay too long...mostly to save up cash for all the unexpected stuff that's popped up, but i think I have most of what i need now...just a matter of time.

Last night, I got the main bearings and crank put in, as well as sealing the 2 halfs of the block. I'm hoping i used enough of the gasket material...it said a thin layer put on w/ a foam roller would work... Guess i'll find out soon enough


Lower half w/ new bearings
Attachment 23667


Upper half...new bearings w/ assembly lube gunked on...

Attachment 23668


Ready to go back out into the garage...
Attachment 23669



Today, i opened and cleaned up the oil pump then installed that with new seals and gasket...

Not sure if i put the Front Crankshaft oil seal on the right way...I'm pretty sure i have it flipped around the wrong direction. Anyone know if the section that is flat OR the section that you can see the spring should be facing away from the engine?

I think this is wrong...you can see the spring inbetween the seal grooves facing away from the engine...

Attachment 23670

I figure that's easy enough to fix, so moved onto putting the new pistons in, along w/ new bearings for those too. T

Attachment 23671

his is the first time i've ever installed a piston, so took me a while to figure out how to use the ring compressor correctly, but after doing the first, the last 4 were cake.


Attachment 23672

Attachment 23673

Attachment 23674

Connecting rods w/ assembly lube
Attachment 23675

Attachment 23676


So tomorow gonna tackle the oil pan, and probably put the head back on if i can get someone to help hold it to torque it down. Oh yea..also wanted to double check piston/valve clearance... had the head decked when i had the valve job done...the block didn't need decking...just wanna be extra sure nothing crashes on the first startup.

More to come later...

RE: Rebuild Progress
 

Most impressive. Keep up with the posts. What has this cost you so far?

RE: Rebuild Progress
 

Much MUCH more than i planned on spending when i started... haven't really even added it all up yet...

Labor:
3 angle Valve Job & Porting ~600
Turbo Rebuild ~400
Engine Cleaning/Inspection/Boring/crank polish... 500

Parts:
Main & Rod Bearings ~200
OS2 Pistons w/ Rings ~400
hardware (headbolts, Rod bolts, exhaust studs, nuts, etc...) at least 300 so far could easily be 4 or 450...this has been a big killer
S60 style exhaust Manifold ~300
Seals/gaskets ~ 100
Water pump 80
timing belt stuff (tensioner,pulley,...) 150


i didn't intend on getting this far into it when i first started (originally was just gonna swap an auto for another auto transmission, plus do a few seals)... but it kinda spirialed out of control once i pulled the head and checked my piston and cylinder wall measuremetts.. Figureed if i was going this far, might as well go for broke... So spending all the extra cash definitly slowed the project to a crawl...

At this point i just want to double and triple check everything to make sure there's no stupid mistakes... Not a project i want to do anytime soon again.

RE: Rebuild Progress
 

Looks really good!!!
Yes that front crank seal is in backwards. The spring always goes inwards.

RE: Rebuild Progress
 

I'm most impressed with your self-belief in tackling a complex job such as this.

It looks to be coming along well - and the photos are great.

Like Tech says, the seal is back to front but, all things considered, I reckon you've really done well to date.

Keep the pictures coming and also keep all of us forumists informed of your progress.

Good luck!

RE: Rebuild Progress
 

I was just taking a look at the VADIS program, and came across a section on 'sealing micro enclosed screws'. Never heard of this before, and i definitely don't have any of the Thread seal stuff they mention...Unless this is something i can pickup at any auto parts store.

Have you ever used this before Tech?



Here's what it says on the writeup:

Then it shows the locations of the screws...looks like water or oil connections use this stuff.

Attachment 23657


Exhaust Side

Attachment 23658



Intake Side

Attachment 23659


Engine Front

Attachment 23660

Engine Rear

Attachment 23661

RE: Rebuild Progress
 

I'm just going to throw this out there, but you have the makings of a great How-to here for the rest of us... Consider taking more photos and writing a post... ;0)

RE: Rebuild Progress
 

Regular Locktitie will work fine.

RE: Rebuild Progress
 

So what's the best way to put that front crankshaft seal on? It's a lot harder when installing it the correctway :)

I tried putting the seal in the oil pump then installing the oil pump onto the block, but the inner lips just seem to fold over and the spring pops out.

Similar results when i install the oil pump first and try to squeeze the seal inbetween the pump / crank...

Everything is lubed up with plenty of oil...

Gonna try to get something thin inbetween the seal/crank in a little while...need to take a brake for a bit after fighting w/ this for the last 30 minutes...

RE: Rebuild Progress
 

Hey now,

I'm guessing that it is probally a product that is made by Loctite as the company that I work for makes adhesive tape for a number of other companes, including 3M, and we package their products accordingly.

Appearance is everything.

Chances are if you were to try and purchase this from the dealer [:'(]they would be looking for an arm and a leg $$$$$.

If Loctite is used buy the big 3 on production lines in North America, and the world over for that matter, then I would 'go with what you know' [sm=smiley20.gif].

[sm=icon_cheers.gif]

RE: Rebuild Progress
 

A superb job indeed, and I found the source of your drive & motivation which I circled in red.


JPN

[IMG]local://upfiles/6892/96708988574A45AF9384531589ACAF07.jpg[/IMG]

RE: Rebuild Progress
 

The seal is kind of hard to put in but get it started and tap it in some.