Engine rebuild project following blown piston

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Postby paulwatkins » Mon 05.02.2007, 21:52

Friday evening, I finished filling the pas system fluid on the second battery charge and called it a day at that!

Removed the battery again and put it back on charge.
Next morning I decided to give the start-up a go. Reset the trip inertia switch in the battery compartment, slid into the drivers seat, turned the key to position 1, the fuel pump charged up, turned the key again........the engine cranked over for about 3 or 4 seconds then roared into life!

It's alive! :lol:

I then set the timing up to 16 deg BTDC, which was very straight forward - thanks to the write-ups for that! I also did the excercise that mickmick carried out, turning the cas from one way to the other to witness the effect it had on the timing reading.

This also allowed the engine to warm up nicely prior to the running in to come.

Then took the car out for the first of 2 sessions I planned for the initial hard running-in.

I did 10 miles of high rpm, hard acceleration, hard engine deceleration and returned to the garage to check for any leaks. All was good!

Then took it out for the second 10 miles - more of the same. Returned to the garage. Still no leaks!

The car was accelerating really, REALLY well! Sounding nice and smooth, nothing untoward. Pulling nice and straight, and responding well to changes in throttle.

This method of running in is also particulary good for when 2 knob-ends in a crappy Nova pull-up alongside at the lights and attempt to have a go.........I wouldn't normally respond to such juvenile behaviour, but come on guys, give me a break, I was running the car in as prescribed!! :-D

On returning, I let the engine cool down for 45minutes, then did the 20 mile oil and filter change*. The oil was full of silvery residue - I have posted a pic below but you can't really make out the colour of the contaminents.

*tip: loosen the filter and then place a clear polythene bag completely over it before unscrewing all the way out, keeping the bag secure. it catches all the oil, preventing it from dripping all over the exhaust, driveshaft and longeron. I didnt spill a drop!

Replaced the oil with non-synthetic Duckhams 10W40, which I will keep in there for 1500 miles. The filter is the Fram type.

I have been running the car over the past couple of days, and everything seems fine.

On sunday afternoon, I installed a small key switch into one of the blanks near to the steering wheel. This switch replaces the paperclip short that is inserted into the aldl plug for checking fault codes and for putting the car into service mode. It's a nice and simple install that will make a fairly easy job, even quicker and easier. The parts cost me the grand total of £5.00 :D and took me about 20 minutes to complete.

I then gave the car a good wash and polish. I bought some Maguires products following the recommendations from some of the guys on here. I must agree, that it is really good stuff........especially the polish which is real easy to put on and take off leaving a lovely shine.
I then took some pics. See here
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Postby isuzuimark » Thu 08.02.2007, 16:47

the silvery stuff is most likely assembly lube mixed with oil. see if you can get it out with a magnet to make sure.
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Postby paulwatkins » Thu 08.02.2007, 17:17

isuzuimark wrote:........see if you can get it out with a magnet to make sure.


No-can-do! I've taken it down to the refuse centre already. :oops:
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Postby GPT27 » Fri 09.02.2007, 19:47

Congratulations on your achievement Paul.

Are you gonna get her Dynoed to see how she runs? (Seeeee how she ruuuuns).
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Postby paulwatkins » Fri 23.02.2007, 16:27

I've been running the car for 2 full weeks now, covering 600 miles. (with a 1 week break inbetween while I went on hols). No problems to note. It is running smoothly and is very responsive.

It went for an mot last week, and failed on a split outer cv boot! Passed all the emmissions tests with flying colours! This was the one test that I was not entirely sure how i would get on!

Changed the cv boot yesterday and the work has been checked and approved, so i now have a nice new mot cert.

Still planning on changing this Duckhams oil out at 1500 miles - hopefully this will be done before Donny.

I've got a very slight oil leak from the gearbox (2 small drops on the garage floor) I'm not sure where exactly it is coming from. I haven't had chance to have a good look yet. It seems ironic that it is coming from an area that I didnt do any work to :)
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Postby paulwatkins » Sat 24.02.2007, 17:27

Just had the peco exhaust system fitted, and it sounds great! :twisted:

I took it to a local garage who charged me £30 to fit it. It took the guy about an hour to remove the existing and install the peco.
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Postby stevieshag » Sat 24.02.2007, 17:53

:burnout: I did say you would love it..

Glad your project is coming together now.. Watch out for the project creep.. :!: :!:

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Postby paulwatkins » Sun 25.02.2007, 16:33

stevieshag wrote:.. Watch out for the project creep..


I think i'll just enjoy the car for the time being....but future projects would include:

1. Front brake upgrade
2. Chip upgrade
3. Install short shift kit (which is sitting on my shelf!)
4. Improve the sound system
5. Replace the fasteners on the front and rear valance, and wheel arch liners for stainless (again, the set is sitting on my shelf)


.......and i guess there'll be others! :twisted:
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Postby paulwatkins » Wed 21.03.2007, 21:23

Changed the Duckhams out after 1000 miles and prior to going up to Donny. Replaced the oil filter and refilled with Castrol Edge Sport 0W40.

The run upto and back from Donny went without incident. Everything seems fine and the engine is running well, extremely well!

So I guess, this is the end of this particular project thread!

It really has been an incredible journey for me....from knowing eff all about car mechanics, to being pretty confident to tackle any job that may spring up.

Thanks to everyone who provided me with support during this time - be it technical, moral, assistance, advice, guidance, demonstration (cheers pinky!) etc. I wouldn't of started it without your encouragement, and I certainly would not of finished it if it wasn't for you lot!

This project had been a great credit to LEC.

Cheers, Paul


THE END........UNTIL THE NEXT PROJECT!!!!! :twisted:
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