Marky Mark's Astor 6

[mackat]

Cool - Thanks Niall

[mackat]

Gave my head a quick polish... ohhh errr...!

[attachment=22733]

Will give it another go as I'm not overly happy with the result

[attachment=22734]

[mackat]

No real progress, have slowly been stripping parts from the old engine, cleaning them up and putting to one side for the time-being.

The exhaust manifold nuts on the new engine have proven to be a bugger to take off. 4 of them have welded themselves to the bolts. Ended up having to cut them off, which has left a couple bolts badly damaged.
Is there a tool for extracting old bolts?

Oh and finally for having 122k on the clock the old engine head is looking rather clean:

[attachment=22801]

[Paul_13]

Mini stilsons?

[mackat]

Mini stilsons?

maybe, but I don't think I'll get the grip on the bolt. Might have to be a screw/bolt extractor bit.

[Paul_13]

http://www.irwin.com/tools/browse/screw-...extractors

That's for bolts, I'm struggling to find one for studs

[306Dan]

http://m.ebay.co.uk/itm/150999676976?nav=SEARCH

I use the Clark one of these. Not had any problems yet and haven't bad one that won't budge

[mackat]

Cheers chaps - wish I'd seen your replies before taking a dremel to the nuts.. (not as painful as that might sound!)

Might have to invest in some bolt-extractors for future reference.

Now just to remove those studs?!?

[Seb_Ryan]

Stud extractor? Or double nut it and turn the inner nut anti clockwise

[PocketFighter]

Mark it's looking wicked mate - I've only just seen your PM by the way, I can't reply as still not done enough posts! Lol let me be a forum whore so I can reply!

Bertie (Mr Fighter) lol

[PocketFighter]

Bit of an update on Mark's behalf, dropped by his on Saturday, most of the engine back together, had an issue with one of the rear engine mounts .... Then dropped by again today after work as I saw him as was passing by and he had the motor back in the chassis, got as far as putting the manifold back on... That's all I have unfortunately! Was only a quick chat really but car is coming on nicely I must say!

Mental seeing 3 diff phases of pugs on his drive lol

[mackat]

Thanks filling in my updates Bertie


- Have been off the forums of late due to health and lack of luster, I swear every nut/bolt has been welded on by a previous owner.

I'll update the thread over the next day or so but some photos are always nice

Thought I'd tackle the front suspension while the engine was out:

[attachment=23399][attachment=23400][attachment=23401][attachment=23402][attachment=23403]

[Paul_13]

Good choice

[mackat]

B8's front and B6's for the rear - The B6's still need to go in.

Ohhh and f@*kin' 4 hours to do the first one!
15mins to do the next, once I knew how to do it.

[mackat]

Picked up the fixed/rebuilt gearbox - 5min job to attach it up to the engine.
Hammerited all the wire and clutch mounts:

[attachment=23420]
[attachment=23421]

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Rear engine mounts where a nightmare - Both on the main mount itself and the smaller mount which attached to the front beam.


I think it took me a good couple of days trying to get them out:

[attachment=23423]

I bought a vibra-technics mount which is 70mm, it's supposed to fit into the mounting hole which also happens to be 70mm - Errrrr....?!?!
Ended up taking 1mm off the engine mount, with a shed load of geese and the trusty rubber mallet finally got it to fit:

[attachment=23424]

[mackat]

I think at this point I got a bit fedup with project and wanted it finished asap, so no photos until the engine was in and with most cables hooked up:

[attachment=23439]
[attachment=23440]

[Niall]

Awesome work mate!

[PocketFighter]

Can I add... Definitely drives nice! Love that all the power is pretty much spread out across the range, Mark has done a wicked job on this, can't wait to see the finish product!

[7057sam]

Looks great

Really flying along now,when's the first start ?

[mackat]

Thanks Chaps -


Has been started already - BIG shout out to Ryan AKA 306gtiparts and his eBay Shop who I bought the engine and a couple other bits from.

The engine started first time, was a bit rough for the first couple of minutes, then started to smooth out - Every time the engines started it's been running smoother and smoother - Plus the exhaust is quietening down (to my relief)

I had a small problem with the ICV:

[attachment=23455]

Cleaned it up and the tick-over is just about sorted, but I think a new one will fix the idle completely

As Bertie mentioned, he's taken her out for a spin (and yes, the tyre pressure was really low)

Some more photos:
[attachment=23447]
[attachment=23448]
[attachment=23449]
[attachment=23450]
[attachment=23452]

Things left to do:

Rear B6's to be installed and torsion bar hight dealt with (msg to Stef is in order)
Exhaust needs lowering as it's catching on the bumper
Upper strut bar installing again

I'm picking up a drivers door, rear bumper and fogs this coming weekend.

Then it's colour coding and the interior

[mattsrallye]

That looks damn fine on those wheels!

[mackat]

That looks damn fine on those wheels!

Cheers fella!

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Put about 50miles on today - and now I've got a couple quirks:


-Battery light is constantly on when the key is out
-Can turn fans on, windows work without the key
-First click on the barrel battery light goes out
-Airbag warning light occasionally flashes

[attachment=23459]

[PocketFighter]

Somewhere is still getting a live feed mate

[7057sam]

Nice one mate

Still got time to get it to fcs and join me in team astor

[mackat]

Nice one mate

Still got time to get it to fcs and join me in team astor

Would have loved to have gone, but I tend to work most weekends

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Managed to pick up the rear bumper and non-dented drivers door

[attachment=23709]
[attachment=23710]

Although was quite liking the banger style

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lol... not that I got any photos with them on.. d'oh!

[mackat]

Finally got around to fitting the rear Bilstein b6 - damn the ride improved over whatever came out:

   

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Ohhhh and I managed to find out the problem with the old engine:

   
   


Bent valves??

[Paul_13]

Yep they'll be bent!

[mackat]

Yep they'll be bent!

Shouldn't have effected the head?

[Niall]

Yep they'll be bent!

Shouldn't have effected the head?

Could of done. To be honest though, looks like its only tickled the pistons so i reckon you may get away with new guides, new valves and a regrind.

[mackat]

Yep they'll be bent!

Shouldn't have effected the head?

Could of done. To be honest though, looks like its only tickled the pistons so i reckon you may get away with new guides, new valves and a regrind.

tbh was umming and ahhing whether to have this head port and polished or just to scrap it?
Taking up space which I could do with.