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Mk1 F4R/172'd Track Car Project [Year 3 - Engine and Chassis Rebuild]
ValverInBits
Re: Mk1 Hybrid Project
Day 55
Set about fitting the cambelt tonight, as I wanted to try and get the engine in on Friday. Started by removing the alternator setup, then the bracket holding the power steering pump and pipes on. After those were off, I removed the covers for the cambelt, which looked relatively unused.
The first problem I hit was the type of bolts holding one of the pulleys and the waterpump on were female torx bits, which I did not have, so couldnt really do much. I had sourced a pair of Volvo brackets for the alternator setup, allowing me to run the car with no power steering pump. Unfortunately I could not use the Volvo alternator, as the pulley is only 5 rib, I needed it to be 6.
As I couldnt do the waterpump or cambelt without the female torx bits, I trial fitted the alternator setup, using the original Valver alternator. Everything went on as it should, the only thing missing was a belt. The original belt was 1040mm, I needed one that was between 800-830mm.
Day 56
I didn’t manage to get the cambelt fitted yesterday, due to not having the female torx bits needed for the waterpump and one of the pulleys. After managing to find a set of bits this morning, I got on with doing the cambelt and waterpump. I also eventually managed to get hold of an auxiliary belt, so everything could be built up at once.
After removing all the cambelt covers, and turning the engine over by hand until the top two timing marks lined up, the crank was locked to stop it from moving once the cambelt was removed. After locking the crank, I removed the tensioner, then took the belt off.
After removing the cambelt, I needed to remove the idler pulley. There was another cover hiding the two bolts for this, which proved to be a nightmare after one of the bolts rounded off. I had to drill the head off the bolt, then use mole grips on the remaining thread to remove it from the block. Once it was removed, the idler pulley bolts could be seen, which brought along the next problem.
After trying to undo the nuts with an allen key, it seemed they were trying to round off as I tried to turn them. I ended up having to go out and buy a 6mm allen key socket, which worked in getting the two bolts off, which were stupidly tight. Once the new idler was fitted, and the cover replaced with a new bolt, the next job was to fit the new cambelt and tensioner.
The cambelt went on easily, and all the timing marks lined up. Then fitted the tensioner, and adjusted the tension and tightened up the bolt to lock it in position. Then I turned the engine over by hand a few times, and checked the tension again. It needed adjusting slightly, so after that, I turned it over again to check everything was ok.
After I was happy everything was tight, I re-fitted the cambelt covers and the bottom crank pulley. The last thing to do was fit and tension the auxiliary belt, which drives the alternator and waterpump from the crank pulley. Once the belt was fitted and tensioned, the engine was near enough ready to go back into the car. I swapped a few things over from the other engine, like the gear linkage and the auxiliary waterpump.
Day 55
Set about fitting the cambelt tonight, as I wanted to try and get the engine in on Friday. Started by removing the alternator setup, then the bracket holding the power steering pump and pipes on. After those were off, I removed the covers for the cambelt, which looked relatively unused.
The first problem I hit was the type of bolts holding one of the pulleys and the waterpump on were female torx bits, which I did not have, so couldnt really do much. I had sourced a pair of Volvo brackets for the alternator setup, allowing me to run the car with no power steering pump. Unfortunately I could not use the Volvo alternator, as the pulley is only 5 rib, I needed it to be 6.
As I couldnt do the waterpump or cambelt without the female torx bits, I trial fitted the alternator setup, using the original Valver alternator. Everything went on as it should, the only thing missing was a belt. The original belt was 1040mm, I needed one that was between 800-830mm.
Day 56
I didn’t manage to get the cambelt fitted yesterday, due to not having the female torx bits needed for the waterpump and one of the pulleys. After managing to find a set of bits this morning, I got on with doing the cambelt and waterpump. I also eventually managed to get hold of an auxiliary belt, so everything could be built up at once.
After removing all the cambelt covers, and turning the engine over by hand until the top two timing marks lined up, the crank was locked to stop it from moving once the cambelt was removed. After locking the crank, I removed the tensioner, then took the belt off.
After removing the cambelt, I needed to remove the idler pulley. There was another cover hiding the two bolts for this, which proved to be a nightmare after one of the bolts rounded off. I had to drill the head off the bolt, then use mole grips on the remaining thread to remove it from the block. Once it was removed, the idler pulley bolts could be seen, which brought along the next problem.
After trying to undo the nuts with an allen key, it seemed they were trying to round off as I tried to turn them. I ended up having to go out and buy a 6mm allen key socket, which worked in getting the two bolts off, which were stupidly tight. Once the new idler was fitted, and the cover replaced with a new bolt, the next job was to fit the new cambelt and tensioner.
The cambelt went on easily, and all the timing marks lined up. Then fitted the tensioner, and adjusted the tension and tightened up the bolt to lock it in position. Then I turned the engine over by hand a few times, and checked the tension again. It needed adjusting slightly, so after that, I turned it over again to check everything was ok.
After I was happy everything was tight, I re-fitted the cambelt covers and the bottom crank pulley. The last thing to do was fit and tension the auxiliary belt, which drives the alternator and waterpump from the crank pulley. Once the belt was fitted and tensioned, the engine was near enough ready to go back into the car. I swapped a few things over from the other engine, like the gear linkage and the auxiliary waterpump.
Re: Mk1 Hybrid Project
Day 57
Now the engine was timed up, and the new belts fitted, it was ready to be dropped in. It didnt take long to get the engine sat back in the car, only about half an hour. Once the engine was in place, the mounts were bolted back in, and the engine was fully supported. I needed to go and buy oil and coolant, so I went to get it before doing anything else.
Once I had everything that was needed, I connected everything back to the engine. Radiator and the associated piping was done first, then things like throttle cable, clutch cable, engine loom connections, map sensor, manifold downpipe, exhaust and fuel lines.
Next, I connected the ECU to the loom, and reconnected the battery. Then filled the engine with oil, and filled up the coolant. It was ready to be started for the first time…
http://www.vimeo.com/2127842 (Please ignore the commentary by drunknmunky
)
It started first time, and the cambelt had been fitted correctly, which was the thing I was most worried about. Now that it started and ran, I needed to bolt the hubs to the shocks properly, fit the new track rod ends, set up the tracking and get the car off the axle stands. Once all that was done, I took it for a quick drive down the road without a bumper or bonnet, to see if everything was in order. The difference was unbelievable, it was like a completely different car.
After the quick drive, I took it back home and re-fitted the bonnet and bumper. I also noticed a slight leak from the gearbox while this was being done, which I didnt have time to look at as it was late, so thats a job for the next few days.
Day 57
Now the engine was timed up, and the new belts fitted, it was ready to be dropped in. It didnt take long to get the engine sat back in the car, only about half an hour. Once the engine was in place, the mounts were bolted back in, and the engine was fully supported. I needed to go and buy oil and coolant, so I went to get it before doing anything else.
Once I had everything that was needed, I connected everything back to the engine. Radiator and the associated piping was done first, then things like throttle cable, clutch cable, engine loom connections, map sensor, manifold downpipe, exhaust and fuel lines.
Next, I connected the ECU to the loom, and reconnected the battery. Then filled the engine with oil, and filled up the coolant. It was ready to be started for the first time…
http://www.vimeo.com/2127842 (Please ignore the commentary by drunknmunky
)It started first time, and the cambelt had been fitted correctly, which was the thing I was most worried about. Now that it started and ran, I needed to bolt the hubs to the shocks properly, fit the new track rod ends, set up the tracking and get the car off the axle stands. Once all that was done, I took it for a quick drive down the road without a bumper or bonnet, to see if everything was in order. The difference was unbelievable, it was like a completely different car.
After the quick drive, I took it back home and re-fitted the bonnet and bumper. I also noticed a slight leak from the gearbox while this was being done, which I didnt have time to look at as it was late, so thats a job for the next few days.
Re: Mk1 Hybrid Project
video soon
Is it quick?
Nick says it was but if you were racing him anything would look quick (only kidding nick
video soon
Christopher
ClioSport Club Member
Z4M
Re: Mk1 Hybrid Project
It was an awesome feeling when it started first time... although i wasn't surprised... you've done it properly, after all.
Nick's dancing made it in the video too... even if he does eat my gherkins.
It was an awesome feeling when it started first time... although i wasn't surprised... you've done it properly, after all.
Nick's dancing made it in the video too... even if he does eat my gherkins.
R56 JCW
Re: Mk1 Hybrid Project
Sorry for lookin like a tit lol, seriously its quick!!! think it would give pretty much anything for its money
Sorry for lookin like a tit lol, seriously its quick!!! think it would give pretty much anything for its money
wait and see ;)
Re: Mk1 Hybrid Project
i think he knows what im talkin about
yeh its a manual rack now, and he still wont learn to not go into the red on his petrol gauge
i think he knows what im talkin aboutRe: Mk1 Hybrid Project
Short Speedo Vid (Sorry About The Quality): http://www.vimeo.com/2145294
First was standing start to 120mph. Then the power runs were in 5th....last bit was from 2nd until my runway ran out.
Short Speedo Vid (Sorry About The Quality): http://www.vimeo.com/2145294
First was standing start to 120mph. Then the power runs were in 5th....last bit was from 2nd until my runway ran out.
Christopher
ClioSport Club Member
Z4M
Re: Mk1 Hybrid Project
Nippy!
A few vs. vids this week dude?
Nippy!
A few vs. vids this week dude?
Christopher
ClioSport Club Member
Z4M
Re: Mk1 Hybrid Project
Mint... free most of the week
Mint... free most of the week
Christopher
ClioSport Club Member
Z4M
Re: Mk1 Hybrid Project
Watching the vid again... give it some more welly When's peak power on the F7R? 6500rpm ish?
Watching the vid again... give it some more welly
When's peak power on the F7R? 6500rpm ish?
Re: Mk1 Hybrid Project
if your racing 182's put the camera in the rear window
if your racing 182's put the camera in the rear window
R56 JCW
Re: Mk1 Hybrid Project
Ye like u can reach speeds like that on the tyre road
Is it your car "no" till you get a car, worry about it yourself, but u have to pass your theory test first, was gonna comment on the last one you did, you make me laugh danny
Ye like u can reach speeds like that on the tyre road
Is it your car "no" till you get a car, worry about it yourself, but u have to pass your theory test first, was gonna comment on the last one you did, you make me laugh danny
Christopher
ClioSport Club Member
Z4M
Re: Mk1 Hybrid Project
From the vid, it seems so, yeah.
I wanna see how much quicker it is than mine, seeing as it's pretty hardcore! Love it Jord... needs to go more hardcore though
Poly windows
Carbon or fibreglass panels
JP single box exhaust
:evil:
From the vid, it seems so, yeah.
I wanna see how much quicker it is than mine, seeing as it's pretty hardcore! Love it Jord... needs to go more hardcore though
Poly windows
Carbon or fibreglass panels
JP single box exhaust
:evil:
Racing blue 182 turbo :-)
R56 JCW
Re: Mk1 Hybrid Project
shhh ryan
shhh ryan
Re: Mk1 Hybrid Project
want to see these
nice work... looks pretty fast mate. love it.
want to see these
nice work... looks pretty fast mate. love it.
wait and see ;)
Re: Mk1 Hybrid Project
i think someones sense on humour has gone out the window recently
