154 replies to this topic

[millermilla]

I picked up another complete engine from Southampton. Fingers crossed this one is better than the last.
 

 
The crank looks spot on and the main bearings look like new. I measured the crank and it is well within tolerance.
 

 

 
Piston rings are right at the outside of the tolerance limit so I will be fitting a new set.
 

[millermilla]

Engine mounts all painted.
 

[millermilla]

I have removed the yoke for the clutch cable and have converted to a concentric slave cylinder.

 

 

T piece. The top outlet will have a bleed nipple fitted.

 

 

I'm replacing all the gearbox gaskets and seals so decided to take a quick look inside and it all looks good.

 

[millermilla]

Lots of new engine parts so time to start putting it back together at last!

 

 

Bores refaced ready for new rings

 

[millermilla]

New piston rings measured and fitted.

 

 

Bottom end back together

 

 

 

Now just for some head work

 

[Luke1380]

Really nice project.. Will follow this good job .... Luke

[millermilla]

Gearbox painted after replacing all the gaskets and seals

 

 

Head all ready for a rebuild.

 

 

New cambelt kit and water pump.

 

 

It took about 3 goes to get the right angle. Even had to remove the front pulley to give an extra couple of cm's

 

 

Somehow I managed to get it in without denting the wings

 

 

All engine mounts on, just need some adjusting

 

 

Engine looks a bit too high, I'm not sure If I have the lower mount fitted in the right holes. The bonnet does fit and close though with about 1mm clearance.

 

 

If anyone knows where the mount should go on a 2010 on subframe please shout.

 

 

I think the exhaust manifold is going to go. The twin pipe one doesn't really fit.

 

[Ben_O]

Cor you got that in quick!i was expecting weeks and weeks of updates and then it go in.

You don't hang about.

Looks great

 

Ben

[Laundrymike]

Great project and nice attention to detail

[jamesmpi]

Excellent project.

Just a thought have to looked through the 16v mini owners forum?
http://www.16vminiclub.com/forums/

They might be able to help answer some of your questions....

[silve1999]

following thread, very nice work mate, it will be done in no time! looking forward to seeing this beast

[millermilla]

         I've not updated for almost a week. Xmas kind of got in the way a bit but I've still been very busy but I'm at that stage where the devil is in the detail and the little fiddly bits take hours.

 

        I've finished all the engine bay wiring now and have had it running for a few seconds with a bit of fuel sprayed in the inlet. I've fitted a single downpipe manifold place of the twin pipe one as it fits with no body mods however I do have a 4 branch manifold coming which I may fit at a later date.

 

       I bought a new plastic reservoir mini clutch master cylinder which does not clear the manifold when fitted one way round or the brake relocation bar the other way round. The tin master cylinder fits perfectly though.

 

      Just to give an idea on one of the fiddly little jobs the original crank sensor position only gives about 3mm clearance between the wiring and subframe so I've removed it and twisted it 45 degrees then re-tapped the hole and re-fitted.

 

 

 

 

 

Almost there but still got to plumb the cooling system and choose a radiator and fan.

 

[silve1999]

looks really nice in there, the engine really suits the bay! where are you gonna put the rad and fan? :)

[millermilla]

I sorted out the exhaust system today, took me all day as it was  aright pain to get right. I used a flexi coupling which I bought new and the rest it all cut and shut off the old Astra system. I've decided the keep the CAT for MOT purposes.

 

 

 

[millermilla]

Return to tank fitted. I had to remove the tank and flush out as some swarf from the drill ended up in the tank.

 

 

 

New MAP sensor location

 

 

 

I found an air filter that fits perfectly. It's a motorbike filter, can't see it being a problem other than that it will need cleaning very regularly.

 

 

 

Octane plug location