It's an engine out job..
Discussion
Well we couldn't hunt down the rattle in the top end so it looks like we need to dig a little deeper 
never mind, didn't have anything to do at the weekend anyway !!
cams looking pretty good
EDITED TO ADD
These were the symptoms..
Engine ran fine at idle and up to around 3,000rpm
above 3,000 rpm there was a serious metallic rattle.
the cause
Low oil level caused by leak on rear bank turbo.
diagnosis
Knackered big end (and little end!) bearings.
repair
Engine out and rebuilt
never mind, didn't have anything to do at the weekend anyway !!
cams looking pretty good
EDITED TO ADD
These were the symptoms..
Engine ran fine at idle and up to around 3,000rpm
above 3,000 rpm there was a serious metallic rattle.
the cause
Low oil level caused by leak on rear bank turbo.
diagnosis
Knackered big end (and little end!) bearings.
repair
Engine out and rebuilt
Edited by obes on Tuesday 17th October 21:17
Heres the latest !
IC box off and various bits stripped out..
First we accidentally discovered the cat was loose !! ....
so heres matt de-catting !
the offending item... interestingly enough, a metal cat, not a ceramic one.
Soon had it re-welded and back on
Turbo showing a bit of play, but pretty much OK
exhaust side
intake side
And here's the rattle. two stretched chains and the right hand tensioner not tensioning.
O.
IC box off and various bits stripped out..
First we accidentally discovered the cat was loose !! ....
so heres matt de-catting !
the offending item... interestingly enough, a metal cat, not a ceramic one.
Soon had it re-welded and back on
Turbo showing a bit of play, but pretty much OK
exhaust side
intake side
And here's the rattle. two stretched chains and the right hand tensioner not tensioning.
O.
, the tart !
Going 2.5 to 3 is pretty simple. Needs new brackets and a few bits and bobs.....
...and a 6 speed box & M400 linkage....and some T28's instead of T25's.....and an MBE ECU and Loom. Gulp. not that simple after all !
of course there's always the lightweight and lots of room for cooling 4 cyl option(s)..
...and a 6 speed box & M400 linkage....and some T28's instead of T25's.....and an MBE ECU and Loom. Gulp. not that simple after all !
of course there's always the lightweight and lots of room for cooling 4 cyl option(s)..
ahaughton said:
Nice big Audi engine in there then Owen?
This might just squeeze in Adrian
http://cgi.ebay.co.uk/AUDI-S4-ENGINE-
this definitely will
http://cgi.ebay.co.uk/Ford-Zetec-2-1-
and with a bit of messing about...
http://cgi.ebay.co.uk/COSWORTH-OPEL-V
I think i'll be going for the 3.0 duratec tho !
Progress Report!!
Well, it's out !
.
Engine bay looks positively huge !!
.
Further inspection around the sump and windage tray revealed some worrying bits of engine
.
With the sump off and the engine turned up on its front we found the bearings all spun! Crap in the sump is all bits of big end!
moral of the story, keep checking your oil !!!!!
Well, it's out !
.
Engine bay looks positively huge !!
.
Further inspection around the sump and windage tray revealed some worrying bits of engine
.
With the sump off and the engine turned up on its front we found the bearings all spun! Crap in the sump is all bits of big end!
moral of the story, keep checking your oil !!!!!
Turbo's are over at turbo technics for an overhaul. Should get those back tomorrow. £390 for the pair with new bearings and seals. One of them was leaking quite badly, the other wasn't bad but it's daft not to renew them both while they're out. Interestingly enough, it was the rear one that was in worse condition, even though the front one gets considerably more cooked !
I looked onto getting some cast manifolds made but it's a fair bit pricey for a short run so they will be be re-welded and strengthened.
New crank, trick rods and all new bearings on the bench ready. New head set on it's way. Also have new shrouded turbo oil feeds and new gear change cables. Also a new clutch.
New exhaust system parts also ready to go. Will probably make both the cats and silencers bolt in/out
Designing up some shorter solid intake pipes too.
Have been thinking about water/air chargecooling, using a small chargecooler on each turbo exit. Real advantage is that you get loads of air lenghth and volume out of the intake. Should give a big improvement to throttle response. Also allows for a small boot where the intercooler used to be. Pretty sure this'll have to wait for another day though as I just need it back on the road ASAP !!
Oil cooler and pipework ordered. I'm going to be making some Cundyesque modifications to the side pods and mounting the cooler there. Am also running some extra ducting from the front of the car to the front turbo.
Lots of wiring to do too. The old loom is looking a bit shabby, so i'll be soldering like a mad man most of the weekend. Will probably move the battery and the ecu into the cabin.
Plumbed in fire extinguisher also going in.
Nitrons and dymags orders imminent and then there's just the airjacks ......
I looked onto getting some cast manifolds made but it's a fair bit pricey for a short run so they will be be re-welded and strengthened.
New crank, trick rods and all new bearings on the bench ready. New head set on it's way. Also have new shrouded turbo oil feeds and new gear change cables. Also a new clutch.
New exhaust system parts also ready to go. Will probably make both the cats and silencers bolt in/out
Designing up some shorter solid intake pipes too.
Have been thinking about water/air chargecooling, using a small chargecooler on each turbo exit. Real advantage is that you get loads of air lenghth and volume out of the intake. Should give a big improvement to throttle response. Also allows for a small boot where the intercooler used to be. Pretty sure this'll have to wait for another day though as I just need it back on the road ASAP !!
Oil cooler and pipework ordered. I'm going to be making some Cundyesque modifications to the side pods and mounting the cooler there. Am also running some extra ducting from the front of the car to the front turbo.
Lots of wiring to do too. The old loom is looking a bit shabby, so i'll be soldering like a mad man most of the weekend. Will probably move the battery and the ecu into the cabin.
Plumbed in fire extinguisher also going in.
Nitrons and dymags orders imminent and then there's just the airjacks ......
Thought i'd post an update !!
The turbo's are back from Turbo Technics with new bearings and seals..
and i've put some ducting from the front scoops to the brakes and up the tunnel.
(i'll sort something put for the Hvac ones I took out later !!)
The extinguisher's in too.
(modded the rails so Haze can reach the pedals while the seat's out !!!)
Made a couple of brackets to hold the Defi display and Control Unit
Nearly there !!
The turbo's are back from Turbo Technics with new bearings and seals..
and i've put some ducting from the front scoops to the brakes and up the tunnel.
(i'll sort something put for the Hvac ones I took out later !!)
The extinguisher's in too.
(modded the rails so Haze can reach the pedals while the seat's out !!!)
Made a couple of brackets to hold the Defi display and Control Unit
Nearly there !!
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