Ben306 Rallye Thread

[ben306]

The Head back from the engineers







Head gasket on



So much easier with the use of a ramp



The head on and torqued down



Plugs, coilpacks and exhaust back on



Manifold and everything back on



Finally, the new sump guard on



All in all its had

Head tested and skimmed
All new head related gaskets
New super 4 spark plugs
New top engine mount and new chocks made up.
Exhaust manifold welded up
New sumpguard with additional strengthened sections
Full service, oil, water and filters
Cambelt, pulleys, tensioners
Waterpump
Fan belt
Thermostat
Probably more but cant remember.

---

well it managed 2 days /140 miles before I started getting a knock, so its been parked up waiting investigation.

Managed to get it back on the ramps last night and its spun a bearing.

Looks like all the hard work is gonna have to be done again, this time with a bottom end rebuild.

luckily I heard the knocking straight away and the car didnt do more than about 3 or 4 miles at low revs.

There isnt too much in the way of damage to the crank or cups, very little marking, waiting to see if you have any tolerences in the shells. Measured 50mm on the crank and 49.9mm on the one that spun, the cups where all the same.

But the way my luck has been Im not expecting it to be that easy.

---

Well the rallye was finally alive again over the weekend. Massive thanks to my brother (Jack aka top mechanic) who did the rebuild for me, I pretty much watched and got in the way.

All in all its had the top end refurbed, then the bottom end died so its had a full engine rebuild.

From memory its had all of the below. Most items have been increased performance/upgraded items where possible

New super 4 plugs
Head skimmed, tested, polished and cleaned up
New head gasket (2 times round )
New head bolts
New inlet/exhaust/thermostat housing gaskets
New fire ring and exhaust fitting kit
New oil (2 times)
New coolant (2 times)
New power steering fluid
New gearbox oil (2 times)
New gearbox driveshaft oil seals
New clutch kit
New thermostat
Fresh bottom end from Birk which turned out to be knackered, I managed to salvage the crank and thats it.
Fresh piston and rod
Fresh crank, polished, balanced and checked
New big end bearings
New shell bearings
New crank oil seals
New waterpump
New piston rings
New bottom hose
New powersteering cooler pipe
New sump guard
Engine bay steam cleaned
Rust in engine bay treated and painted (needs final touching up)
New cambelt kit, pulleys/tensioners
Various engine bits painted
New Aux belt
New top mount and chocks
Wheels re done
New Ferodo ds2500 pads
Will be re painting the calipers etc
Towing eye straightened (Following wheel coming off at silverstone and car being lifted by track recovery)
Front bumper insert refixed (Following wheel coming off at silverstone and car being lifted by track recovery)

Probably alot more that I cant think off.


Load of boring photos now (and not in the right order but I cannot be fussed to sort them). Its at FCS in the Top 25 in less than 2 weeks so need to tart it up