2.4T engine rebuild - Shock: It actually runs!

[Gary71]

Rods now back on the crank, using a super funky torque and angle wrench. Beeps once at the preset torque, then beeps again when you reach the angle. The beeping helps when you are fighting the whole assembly on the bench trying to stop it exiting stage left, particularly on the upper rods, as you don't have to look at the display.

A major advantage of working for a car manufacturer is you can borrow really good calibrated tools!



It also logs the final torque for interest and this was between 75 and 85nm.

I've also made a set of rod/chain supports using some strip material from B&Q. It's all aluminium, the black stuff is quite a bit springier than the raw part, but it's all they had in. Should do the job just fine I think. 15 minutes to make and it should save a lot of grief during those tense moments putting the case back together.

[Gary71]

Of course I couldn't leave it there could I?



Tempting as it is to push on and fit the other case that's enough for tonight.

[AndrewSlater]

Looking good Gary - good to see progress.

Tempting as it is to push on and fit the other case that's enough for tonight.

I think that is a wise decision as the next stage is best done with a clear head.

[911hillclimber]

And speedy nimble fingers!
Looking good Gary, very major step about to be taken.

[Gary71]

I seem to have ended up at the pub because it was sunny so no further work tonight!

[Gary71]

I've been grabbing a few hours here and there to progress things.

A very stressfull 30 minutes had the cases back together and torqued up.



Other non visible jobs were fitting a few external parts to the case, the timing chain ramps inside and the oil pressure relief pistons.

Tonight I replaced the spigot bearing on the flywheel and made a start on the pistons/barrel assemblies. The ARP tapered ring compressor is wonderful, a bit expensive for a one time use dedicated tool, but it's so easy to use and zero risk of ring damage. (The rings I bought from Hot66 about 6 years ago!)



Tomorrow I hope to have all six assemblies on the case and maybe even put a head or two in place. It will depend just how much of a fight the gudgeon pin circlips decide to be!

[Gary71]

Big day in the garage today, some 10 hours, but also some progress you can actually see.




And where I finished for the evening:


Almost without a hitch other than improvising a ring compressor when the oil scraper decides to exit the bottom of the final cylinder whilst tapping home the gudgeon pin emergency measures are required!

20 minutes of fiddling but it's back in. The other option would have been to strip the complete side of the engine I'd just built. So motivation was high!



I also took a little video of the proper ring compressor in action. Awesome!
Untitled by Gary Suggate, on Flickr

[sladey]

Great stuff Gary - I watched your video twice

[Gary71]

It wasn't that good

[Darren65]

Great progress Gary, well done.

[911hillclimber]

So you managed not to have one pin C clip fly to infinity and beyond?

Excellent progress, over the 1/2 way mark now.

[bjmullan]

And here's me thinking you would break my record, dam!

[Gary71]

So you managed not to have one pin C clip fly to infinity and beyond?

Excellent progress, over the 1/2 way mark now.

They all went in first time, I guess it's because I covered every possible way into the engine. If I had left one small gap they would have been through it like a shot!

[Gary71]

And here's me thinking you would break my record, dam!

I've not finished it yet!

[911hillclimber]

The thinking bit is next, cam timing

Take you time!
Summer is here now, so get a move on.