Motor Rebuild – (hot-to-trot)

[Doc Fizzix]

Picked up the last batch or parts from GTi coatings

[Doc Fizzix]

I have been working hard over the last week to get the engine compartment ready to put the new motor in.

Here is a picture of the compartment before the cleaning:




Had to put in the new rack, if you have not done this job before then pay someone. This job was helll:






Here is the engine bay with the new rack and partly cleaned, more work needed before the motor goes in this weekend:

[Dave M]

Looks great, Doc! Good luck with the install. Remember all the fuel line and oil pressure transducer connections! They are a monster to deal with after you get the engine totally in and starter installed. Don't ask how I know...

[Doc Fizzix]

Looks great, Doc! Good luck with the install. Remember all the fuel line and oil pressure transducer connections! They are a monster to deal with after you get the engine totally in and starter installed. Don't ask how I know...

Thanks Dave, I am going to spend today geting everything labled and ready for the install, I still have the trany to get back together after putting in the LSD but the motor is ready and in waiting (pictures later today).

As for all the connections and lines, it was a tight fit trying to get everything off in the first place and I took my time and I will imagine it will take me a couple of days to get everything connected again.

[Doc Fizzix]

Update 07/13/06

I was planning on shipping off the exhaust manifold to extrude hone and had it all boxed up but was very concerened that I did not have a ball park figure on the cost. Finally got the cost and decided to pass on extrude hone ($425.00 for the manifold) That is a little more than I wanted to spend on the part since I had to have it re-welded and trued up already costing over $100.00

[Ashaman]

Yeah, that is a crazy price...I checked with them a few years back and the price definitely put a damper on it for me.

Fortunately the manifold is a pretty short path, so it can't affect things too much. Besides, for that price somebody could almost put together a nice stainless header!

[Doc Fizzix]

for that price somebody could almost put together a nice stainless header!

We had talked about doing that also but my tech took one look at the current manifold and then told me that it was not worth it (to him) and then he told me that it would cost $3K (that was his price with a smile) So after these discussions we decided to salvage the manifold as it was by re-welding and porting a little. After the porting and polishing I am sure I will get about the same performance gain (or close to it) as if I sent it off to Extrude Hone and paid their $425

[Doc Fizzix]

Things are just about ready to go, I had the wastgate on the turbo ported to 22 mm.

[Doc Fizzix]

I was hoping to get the motor in this weekend but I want to spend at least a couple more days going over everything to make sure things are ready. Here are some pics of the motor almost ready to put it. I have the old engine hangers on the motor so I do not scratch up my newly coated ones

[Doc Fizzix]

I have the trany now ready to attach to the motor, the LSD is now in place and everything is back together.


Here is the old diff coming out



And here is the new LSD going in

[Monty]

Looking good Good luck with the fitting, found it easyer putting it back in than taking it out when we did Dico`s.

[Doug]

fantastic work!

love them pictures of the work in progress

[Doc Fizzix]

Well, after long discussions and thinking about the turbo upgrade for my motor rebuild I am only going to do the "Thunderbird" upgrade. For now the motor will go back in the car with the original turbo until I run the motor and put some miles on it. Then I will try to put in a Thunderbird IHI as follows:

http://www.robietherobot.com/storm/geo_ ... _turbo.htm

From what I have read about this upgrade and discussed with others, the Thunderbird option will get me about 250 hp with all my mods and so on, that is deffinetly enough to have some real fun.

Just a quick comment. Robie is one great guy and is very helpful with all questions you might have, he really knows these motors!

[nitroman]

Doc, that is my path as well. Our engines will look & perform almost identically!!!

[Doc Fizzix]

Doc, that is my path as well. Our engines will look & perform almost identically!!!

This is the weekend I will get the new motor in the car We have everything ready to go!

I will have to talk with you a little more as I get the turbo upgrade ready

[Doc Fizzix]

Ok, big day today

I had a hard time sleeping thinking about the excitement of getting the motor in today. To start with, I had to get the motor off the stand and then attach the Fidanza flywheel and clutch.

One screw-up

After the motor was in the car I discovered that I had used the blue Loctite and not the red. Hope that is not a major problem down the line. The blots are torqued fairly tight so I should not worry but I am thinking about everything that could go wrong at the moment.

[Doc Fizzix]

Here is the engine compartment cleaned and ready for the new motor. I hope this gives nitro (Mr. Clean) a run for his money

[Doc Fizzix]

As Monty said, going in is a LOT easier. The car is now with a motor again and sould be ready to go after next weekend

[Doug]

awesome, Al!

I'd bet Nitro is jealous cause there is not way to get it that clean without removing the motor and standing in there and cleaning it up close !!

[Monty]

WoW superb!

hope all goes well when u turn that key