[Mk2] [Turbo] My rev2 rebuild log.

[Grazzy]

So after much consideration I have decided to get my engine bay completely sorted. had an oil leak for a while, had the common leak areas addressed and its still spotting from somewhere.

Whats been changed is:-

Changing out rev2 loom and sensors ecu injectors for all rev 3 (bought and entire package from this)
cometic head gasket, ARP bolts, full rebuilt on the head
all belts, bearings + tensioner's
drive-shaft seals, sump pan replaced.
New downpipe (berk) + KO R1 system
engine oil been used is mobile one full syth, gearbox oil Redline MT-90
probs going to change the clutch also (may as well with everything else been change). Have not made my mind up on brand got about £200ish left to spend on this.

Only thing i've purchased so far that i have not been to happy with was the finish on the berk down pipe, well its was shocking.



guessing this is called the "stevie wonder" finish, been sorted at the moment.

but on a lighter note blocks out time to get cleaning & get the paint out.



only one thing I have been struggling to find is drain and filler plugs for gear box. are they the same for all rev's? car is fitted with an LSD gearbox. these plugs needs replacing badly. Ill update with more pictures as the work progresses.

[ashley]

Good effort- get this moved to the Member's section

[Grazzy]

I've decided to replace the clutch, can just see this coming back to haunt me in the future. My question is which one? After this engine build i'm not seeking more power.

Do I use a standard OEM replacement kit, Or is it worth spending twice as much to get a uprated one. I don't know how much power my car is running at the moment. I have changed things since I last dyno my car.

[Grazzy]

Ok just been the garage, I will deffo be needing a new clutch kit:-



surprised this was not slipping.

I was thinking of buying one of these for a replacement:-

http://www.ebay.co.uk/itm/EXEDY-STAGE-1 ... 27e9ec65f4

or should I be looking at something else for the same money, or spending a bit more? or less if I'm going to over kill.

[Grazzy]

Gearbox box clean up



Subframe cleaned up, This was black from dripping oil and scum.



Blocks been has started to be cleaned up almost ready to take the head off




Things left to clean before they go back on



I've got tomorrow off work, so ill be scrubbing the engine bay out. Over the weekend may get the undercoat out as well, Seems like a good time to do this since I can get at everything.

[Grazzy]

Well Close to doing something exciting now



Heads off



After inspection of cylinder 2 there was a very fine mark. Can barley see it with the eyes but you can feels a small grove with you finger nail. So the blocks going to be machined also.

I'm going to be adding forged internals to the engine. decided its a shame to go this far without doing this.

Does anyone have a rev3 inlet cam going cheap?

[Grazzy]

Piston kit has turned up



Wossner 8.0 " 86.5mm
Eagle rods

Bearings are turning up tomorrow,

most of the machine work has also been done. almost time to start getting this put back together. gotta admit getting pretty excited

[2mad]

Very nice looking forward to seeing how you get on .. may go for the same clutch , looks perfect for my build too

[Grazzy]

Very nice looking forward to seeing how you get on .. may go for the same clutch , looks perfect for my build too

did some shopping about got it for £266 delivered.

[2mad]

Good effort- get this moved to the Member's section

Yeah definatly do that .. makes it easier to keep tabs on you project

[Grazzy]

Good effort- get this moved to the Member's section

Yeah definatly do that .. makes it easier to keep tabs on you project

Can some one move this to the members section please

[Grazzy]

And the last bits have turned up. **fingers crossed**

[Grazzy]

Got my hands on ST205 cylinder head. over the weekend. So i'm managed to get hold of an intake cam.

Other news, Everything this afternoon is coming back from the machine shop. New colour for the block is going to be metallic red, I have not decided on what colour I'm going to paint the cam cover yet. thinking may go blue since my intercooler piping is blue.

Should have some photo's of shiny engine parts to upload tomorrow.

[Grazzy]

OK decided, the cam cover is going to be power coated red, that's getting sent off this afternoon

[Grazzy]

Cam covers come back from the powder coaters, Looking good

[Grazzy]

Just like the missing links just turned up



The Crank!!

[Grazzy]

its red , It will be clear coated tomorrow. Left it on the side this morning



Hoping the engine should be built up and ready to go back in the car later in the week.

[Grazzy]

Well had a bit of a setback, turns out Halfords own brand (only brand) high temp engine paint is total pants. even with primer & clear coat (Hycote) was just come off the block. So its been cleaned and repainted again. SO here some updated photo's its in the process of been built back up.

[gnzyza]

If you used the Halfords VHT they are no good for engine blocks. The engine specific or enamel paint I found to be ok.

[2mad]

Wow you've been busy .. shame about the set back .. looking forward to whats next