Dr_Jekyll & Mr_Hyde Estate Project

[dr_jekyll]

Cheers ruan. Tbf i didnt even realise somthing as small as the stop screw being adjusted could throw the ecu out.
Atm the main goal is that i badly need to get this engine done and in and the turbos kinda had me wander off that goal. That being said the best path for me to at least get started seems to be the boost can.
As you say i can always revisit it and some basic knowledge with the boost can could help me later.
Got a chap at work who loves his arduino projects and offered to help and teach me so i reckon stand alone could be the way i go later.

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[dr_jekyll]

Noticed a small scale disaster the other day and think i caught it fairly early thanks to the advise of you guys on the forum [emoji106][emoji106][emoji106]



Basically from what i gather the plates in the oil heat exchange decided to start weeping. Bit of a bastard as only serviced it 10 mins before noticing [emoji23] anyway tooknthe day off work and swapped the exchange over. Bit of a tight job getting the clips off the pipes but was plenty doable and appears to have solved it. So far done 150miles and no more oil in the water.

As it only it was only a small job decided to use the rest of the day to make a start on the new engine.

Tbh never realised how much loom and fuel piping there is on these so spent a fair while taking reference pictures and labeping the loom to hopefully make my job easier later.
As parts came off was shocked to what i found. Pas fluild from the pump was clean and had no smell to it. Seriously clean anti freeze in the block, genuine oil filters, new aux setup that had only recently been done looking at the condition of parts. Even the intake wasnt as coked up as i expected to see. Pretty much looks like this engine was every bit the gem carl chambers made it out to be so very happy!

Ran into another financial hiccup tho. Allowed my tyres to get close to the legal limit so the funds i had saved towards getting the head done last week are now gone again. Made the decision to leave the head on until im ready to send it off to try protect the block.. Dunno if this actually matters?

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[Poodle]

Great news. Block should be fine if it's kept in the dry.

[dr_jekyll]

Still gonna be a while before i get the bits to rebuild it tho so spise it could be better off remaining sealed up.
Espesh when i buy daft bits first. Ended up placing an order on torques_uk for some shiney oil feeds for the new turbo setup. Certainly cheered me up after a pants week at work
Least to say the fittings certianly look sexy and should deffinatley not get any oil return problems [emoji23][emoji23][emoji23]

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[dr_jekyll]

Well the piggy power fiberglass bonnet landed [emoji16] took a very fast dislike to the carbon wrap and bonnet scoop (upon discovering it would mean the bay fuse box needed moving to accommodate it) so pretty much spent the last two days attacking it with a hair dryer and fiberglass.

Basically laid two sheets of matting behind the hole then filled the hole in with several layers of matting till i was back to a good position to blend the surface with fiberglass bridging filler. Had about of an annoying moment tho. Where the strentgh had up and left the bonnet it hadnt held itself in linewhen being fiberglassed. Pretty much got the thing perfect but to me it looks like theres a low spot on the bonnet along the "buldge line", ive worked and worked it with filler but cant seem to get rid of it. My partner thinks im mad as she can't see it so pray it dosnt show up when this things sprayed with the traditional graffati paint.
Just got a badge grill and badge to pick up for it. Was undecided on wether to smooth the badge of too but part of me would like that slight oem look back to the car and to ditch that bloody bra at long last

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[dr_jekyll]

Woke up this morning and saw how bad the bonnet was with the light hitting it and the shadowing. Needless to say another skim of filler and taking some time has sorted it.. I hate body work!

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[dr_jekyll]

Some more small baby steps. Still not got the head off due to illness but cleaned up the turbo coldside and thermostat housing with a brass wire wheel. spent the morning cleaning the last of the glue off the bonnet and gave the bonnet a general wet flat ready for its covering in my horrific graffati paint. Found a few air bubbles but thats maybe half an hours work to rectify.
Itching to get this heaf off and done now. Pretty much got all the bits to rebuild the block once its done. Really need to invest in an engine stand tho. Dont see it being much fun working and painting everything on the floor

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[Eeyore]

Good stuff. I hope you can get a good finish on that bonnet!

[dr_jekyll]

Good stuff. I hope you can get a good finish on that bonnet!

Fingers crossed. Little worried about the heat from the turbo effecting it once its on. Need to try source some of that heat protective vinyl for the underside

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[dr_jekyll]

Finally pulled the finger out my arse and got the head off the motor last night. Ended up having to unbolt the hp pump bracket off with the pump as couldnt find two bolts to use on the jacking points of the pulley and it just wasnt gonna come off with a gentle tap like my last one.
Couldnt believe how easily the glows and injectors came out tbh. Been running a little wd down the side of them every time ive been out to the motor to try make it a tad easier but they practically jumped out at me. gotta get the industrail hoover out and just suck all the leaves off i neglected to do. Hoping to get the head dropped off to a local company start of next week.
Couple of questions tho where ive kinda got a tad stuck.
1. Soaked the bores and deck of the block in wd and laid a rag across it. Will this be good enough to prevent the bores rusting for a few weeks?
2. How the hell does the dipstick come out. Looks like it should come with a tug but tbh a tad scared to yank it.
3. Breather hose seems to have welded itself onto tye fitting on the block. Any ideas on how to remove this nicley or is it gonna be a case of hack the remainder off with a stanley?

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[Uberderv]

That breather will probably need cutting off, the rubber goes hard and brittle over the years.

I'd spray the cloth over the block in WD just to be sure, and maybe keep the cloth held down with a plank of wood.

I seem to remember there is another part in the sump for the dipstick, maybe wait till you remove that to see if it just pull out

[dr_jekyll]

That breather will probably need cutting off, the rubber goes hard and brittle over the years.

I'd spray the cloth over the block in WD just to be sure, and maybe keep the cloth held down with a plank of wood.

I seem to remember there is another part in the sump for the dipstick, maybe wait till you remove that to see if it just pull out

Think thats what its gonna come down to. Not sure what to do about the brether as looking at proper tidying the while setup up. Might run something stainless with two straight silicone joiners.

As for the dipstick just gonna leave it and paint around it for ease.

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Well the tidying up has began to get close to ocd. Wish id of got some more before and after pictures but pretty much should be able to get the idea.


Alternator ended up having a full tear down. Tried to parts wash it but wouldnt touch it. Ended up using a brass wire wheel on a drill and then clear coating with enamel. Fitted two new bearings and the brushes appeared to be fine.

Pretty much same story with the fuel rail, wire wheel and enamel. Pipes have been abit of a pain due to the pitting. Had to sand them back losing the anti corrosive layer on them but then it was already defective if it was pitted. Polished them up and hoping to get away with enameling these tho there a tad more awkward to paint.

Intake mainifolds now clean aswell. Not sure my partner felt so strongly about my decoking methods but this us just awaiting clear coat now.
again thermostat housing is just awaiting clear. Few more unpictured parts to, high pressure pump bracket, lower engine mount, top engine mount.

Heads finally going away tomorrow for skim and rebuild. And then ive just gotta kick my arse into gear to get the block painted and start assembling everything back up.

Main missions gonna be to tidying up onto of the engine. Planning to cut the ribs out of the engine cover to show off the rail and injectors just leaving like a window frame behind it. Got ti figure out how to tuck the loom and some of the fueling system up more neatly.

Bonnets not found its way on yet. Replacment pins have arrived but began to doubt my ability to fill. Think i need to primer the whole bonnet and get it all one colour to inspect it properly.

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[Uberderv]

Awesome cleaning there ? I find cheapo Bio washing powder does a great job on oily bits. I notice you have a 206 reservoir in the engine bay, what made you use that and where the feck is all your brake gubbins?

[mr_fish]

that last picture is a 206 engine bay.

Only way to tidy up the fuel piping is to remove the filter housing and relocate. would see right through to the shiny fuel rail then. But it adds another project in itself to move all that.

[Uberderv]

Oh yeah well spotted lol ?

Quite doable though I reckon MrFish. If you go to a scrap yard and cut the fuel connections off you could make some new pipework which should tidy things up.

[dr_jekyll]

Oh yeah well spotted lol ?

Quite doable though I reckon MrFish. If you go to a scrap yard and cut the fuel connections off you could make some new pipework which should tidy things up.

Yeah was a stolen pic to just show traditional hdi mess lmao. Funny you should mention the fuel lines.. Collected a load last year for that very purpose. Biggest fear is loaing fuel pressure tho by relocating it

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Also on that note i wanted to look at doing away with it for just an inline hidden under the car but just couldn't figure out how to do it

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[JTaylor2005]

Wonder if you could do something with a filter like this and do away with that whole section. Just move the filter to the rear of the engine bay and plum up some way of having the return lines go back to tank rather than back into the filter? Mind you, you may end up needing a better lift pump then...

[dr_jekyll]

Wonder if you could do something with a filter like this and do away with that whole section. Just move the filter to the rear of the engine bay and plum up some way of having the return lines go back to tank rather than back into the filter? Mind you, you may end up needing a better lift pump then...

See somthing like that would be ideal. Could even simply hide that in the arch. Just done a little net research and found what the three pipes are. Tank, hp pump and return. Looking at the diagram and a wee bit confused tbh. In my head ive got it that the return line is nothing more than a tee off from the filter to h.pump line.. But surley that would drop the fuel pressure badly?

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[JTaylor2005]

I will have a look on my car. I believe that the incoming pipe (E1) comes from the in tank fuel pump AND the outlet of the fuel pressure regulator. (Which is then low pressure as it has been released into the fuel systems large pipes and filter housing.

The only thing that wouldn't be able to be catered for very easily would be the thermostatic fuel heater. That has a little bi-metalic flap inside the filter housing that opens and closes to allow fuel to go and flow through the fuel heater (Which is part of the bit underneath the thermostat housing)

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Or the high pressure fuel regulator relief T's into the "S2" pipe after it has left the filter?

[Uberderv]

You can filter it through what you like and it will likely work, I've used an inline filter in the past which was fine although only a temp solution. Keep in mind that the original housing has a few functions which many others won't. For me the most important two are 1. Internal filter is rated at 1 micron. 2. Housing also bleeds trapped air out and maintains a feed pressure to the HP pump.

[dr_jekyll]

You can filter it through what you like and it will likely work, I've used an inline filter in the past which was fine although only a temp solution. Keep in mind that the original housing has a few functions which many others won't. For me the most important two are 1. Internal filter is rated at 1 micron. 2. Housing also bleeds trapped air out and maintains a feed pressure to the HP pump.

This is true. Was having this conversation with frosty last night and think the conclusion in the end was theres just some parts you dont mess with [emoji23] will tidy the pipe work up still tho with the spare connections i salvaged from the scrappy

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[Uberderv]

Yeah you can move it where ever you like. The original fittings have a barbed end, if you cut them carefully you can then use flexi fuel pipe or make a little press to insert them into new Nylon hose.

[dr_jekyll]

Yeah you can move it where ever you like. The original fittings have a barbed end, if you cut them carefully you can then use flexi fuel pipe or make a little press to insert them into new Nylon hose.

Yeah already got them cut off. Was looking at the flexi route but can decide on coloured or clear piping

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[Magenta Sunset]

I think it's just possible to make out a divider in the injector/tank tee.
possibly to allow fuel to escape back to tank when all injectors are closed...
I read somewhere that the ecu times 2 cyls per cycle, one of which is in compression stroke.

[dr_jekyll]

End game on the 3oh6 the other day. Car went from running fine and parking up to not starting the next day. Swapped cleaned sensors etc, swapped hp pump for inown good, traced some naffed plugs and still nothing. Not anything thing on diagnostics testing either. Basically found it to be a combination of things ive declared as the cars end game. Injector massively failing leak off, burnt out engine loom and to top it off cylinder 2 appears to have almost bit the ghost with a stupidly weak compression which would explain why tye bay looks like in undersealed itself [emoji23][emoji23][emoji23]

Stepped my game up abit to push to get this done now, heads come back after being sent away for rebuild. Head had a full strip and degrease by l.A Whitmoores. Pressure test, valves ground, hydro lifters squeezed and inspected, all 4 injector seats milled, victor rienze stem seals, new cam seal and obv a skim.

Got in tge phone today and ordered the new clutch aswell. Gone for a helix autosport 4 paddle unsprung. After the issues with all the cg's i felt a clean slate was needed and that this was the way to go. This will be combined with a luk pressure plate.
Apart from that im pretty much down to the boring bits to get, gaskets, pulleys and new intake/cooler piping.



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P. S does anyone know why the tap talk app wont load pictures?

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[dr_jekyll]

Well this threads become as exciting as a funeral. Lil more progress, cobtacted mardigrasmotorosport about getting a helix solid ckutch made to move away from the cg crap. Lead times apparently 15 working days so ordered that.

Got the head on tonight with the arps. Started off cleaning the block up with stanley blade then used 1200 grit wet and dry with wd40 just to finish it off ready.

Fitted the arp head studs in just giving them a gentle nip with an allen key and using the lube supplied. Cleaned the deck and head wuth brake cleaner and slid the victor reinz on the block
Bish bash bosh, heads on and now awaiting my fuel pump from the girlfriends to fit the cambelt.

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[Uberderv]

Schweet You going for owt fancy fuel system wise?

[dr_jekyll]

Schweet You going for owt fancy fuel system wise?

Still not sure

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[Uberderv]

I've read about building a Frankenpump with the shaft out of a CP185h but there ain't much info, I will message the only bloke who I knows done it if you like? That matched with JTD nozzles would certainly help for a nice high powered clean tune... In the not so distant future I'll will be doing that set up too

[dr_jekyll]

I've read about building a Frankenpump with the shaft out of a CP185h but there ain't much info, I will message the only bloke who I knows done it if you like? That matched with JTD nozzles would certainly help for a nice high powered clean tune... In the not so distant future I'll will be doing that set up too

Atm tad worried about getting larger injectors as struggerling to find a mapper to get the turbo sorted. Might get it going on the r70 and stock and go from there. Limiting factor for me is deffinatley the injectors now

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