303 replies to this topic

[nev_payne]

Right. The "job".

DAY 1 OF PROBABLY 5 - engine out and split.

A head start from the sunday saw the essentials out of the way such as the bonnet, alternator and ignition module, but much much more needed to follow:



Sir D got hungry and decided to munch some human:


Quickest inlet manifold out in the West:


Department of Health Notice - a diet of Minis and too many cakes will make you look like this... and make you have MC-Hammer overalls.


Almost there, Nice tea stand:


Stabiliser comes off, mounts, starter et. all:


Off and away, 4 hours in:


Needless to say I was totally stuck there until the engine crane hoisted me out:


Dr. Vipernoir of Kinspeed Torque Specialists:


A sure fire way to drop Sir D from gassing us:


Bell housing away:


So! The important bit, with videos to follow for BCJames and others with rattling bits. Shaft end gear was sat back in place, idler gear in the middle, just to have a feel of what if anything was rattling away in this department:


Idler was also checked in the corresponding bearing on the clutch house. At this point, if there's play in the idler, get those bearings replaced:


Next - check for play in the crank end gear. The target is 5 to 8-thousanths known as the end float. This was SirD's, 25-thou. Work to be done:


Using a combination of new retaining end, initital bronze end-gear ring, and c-clip we got this down to 10-thou, but more could be found in a thicker bronze ring (currently on order from 'Spares).

Attention then turned to the gearbox to check nothing was to fault in there:


Something amiss in here, no lock tab. Another was also absent in the diff:


The diff itself was worrying. The seal hadn't quite worked so notable signs of oil leakage. Two totally different bearings (cage side was larger than opposite), the planet gears had large grooves sliced into them, and when worked with pressure from both sides, sounded like someone trying to chew on gravel.




While the good doctor got to work on this I tidied up the subframe, brush through and a paint touch up:


Videos to be uploaded, stay tuned for DAY 2.

Edited by nev_payne, 25 April 2012 - 10:19 PM.

[nev_payne]

Videos, firstly Vipernoir explaining the end float gap and how to correct it:



Secondly, the diff's interesting sounds:

[bcjames]

The whole thing apart again Oli! I thought this was another in situ job. Thanks for taking so many pics and the vids. That's rather a lot of play on the diff!

It just brings up more questions in my head. I'm off to think some more now!

[xrocketengineer]

The idler gear thrust washer video needs to be pinned that is great way of doing it! I am going to practice it right now.

[nev_payne]

Day 2 update:

No photos to hand today, there's a few on the camera but it's still garage-side.

The dash is out today to rectify the Fog-Light switch problem and install the cigarette lighter charger. Not quite as clean a job as I'd hoped but that's the nature of the MPI layout. Trying to source the location of a spade connection for the Red-Black cable in the fog light loom turning out to be a pain.

Also found a crack in the upper stabiliser support, not exactly sure what can be done at this point apart from suring it up and 10 flavors of kurust. Lots of parts arriving tomorrow including:

- X-Pin differential
- Replacement MPI tentioner pulley
- 7-17 Speedo drive (acurate speed readings at long last)
- N/S lower engine stabiliser kit (gearbox to subframe)
- Thicker primary gear backing ring
- Diff bearings and seals
- New verto bolt
- New engine mounts (weren't replaced originally, but now they're pealing)
- Other seals and stabiliser bushes, plus consumables.

Edited by nev_payne, 26 April 2012 - 10:05 PM.

[nev_payne]

Day 3: The going gets very tough.

Just a few piccies of today, more tomorrow. Started out at 8:45am, called end at 10:30pm.

The gearbox now has brand-spankers diff bearings, and a 'Spare X-Pin differential. Picture of assembly are on the other camera, but there were quite the selection of tools to get it all into place:


The £50 speedo spindle ontop of the nearly complete 'box:


10pm - almost end of play, due to some unforseen issues with pot joints and a mix up of metric/imperial bolts we were hairs-width close from completing the build at 10:30pm:


Photo's not quite accurate, but the alternator is left to go into tomorrow as well as tidying up the dash board, then fluids, startup proceedure and checking over all work.... and putting some front wheels on (helpful).

Day 4 kick off: 12 noon.

Edited by nev_payne, 27 April 2012 - 11:16 PM.

[bcjames]

That tray of pullers looks very surgical! Great work Oli, you must be a pro at emptying an mpi bay by now.

How far out was your speedo from the factory? I replaced the two drive parts in my old mini, first job I ever did on a car and it took me two days

[MaxAndPaddy]

I thought that too....it looks like a scene from ER

Brilliant pics and video's

[nev_payne]

That tray of pullers looks very surgical! Great work Oli, you must be a pro at emptying an mpi bay by now.

How far out was your speedo from the factory? I replaced the two drive parts in my old mini, first job I ever did on a car and it took me two days

Pah! I dunno about pro, but the engine bay sure did empty a darn sight quicker than the first time round.

The speedo drive was never changed when the previous owner had the gearbox swapped out for a 3.2 Metro Turbo box. Consequently SirD's never had an accurate speedo as long as I've had him and it was one thing that was never seen to (through my own forgetfulness) when Oli Jeynes rebuilt the engine for me.

Seized the opportunity to get everything right before going back on.

[nev_payne]

Day 4 update: Finishing touches and hiccups.

Cracked on from high noon till about 6 today, the engine bay and dash took priority sadly there's still a dash light out on the volt clock.. got to at least be prized out slightly at a later date to change that out. So in went the oil and water, all things mechanical were checked for leaks and so on.



Thus began the MPI start up sequence, oil pressure build up, fuel priming check, throttle position sensor reset and most importantly, lots of swearing when something didn't go right. Initially all checks came off without hassle, on went the wheels and a few final checks to make sure all gears could be selected and used.


We then discovered SirD's front fuse box was causing a lot of very odd electrical cut outs, the quick solution was to clean the maxi fuse connectors and the top of the fuse box to remove the metal oxide. This worked... to a point. 2 miles down the road I switched on the front fog lights for sake of effect... and the fuse box decided it had had enough, and cut off the engine. I have to say though.. when the throttle is closed and SirD is just cruising down the road, he now makes a lovely smooth whine from the new diff. Vast improvement.

After and RAC call, a lot of checking over the possible stray cable "bugger we forgot that one" stray cable, SirD eventually came back to life and I was able to get back home, so long as I didn't use anything heavy on the electricals - high beams, spots, fogs, or a combination of other gizmos. This looks to be a maxi fuse box replacement due to the corrosion so I'm currently sourcing 1. A note to other MPI users - make sure that fuse box is kept clean and dry, especially most are older than SirD, clocking on 12+ years.

Tomorrow I'm looking to tidy up, realign the steering wheel slightly and check over for any leaks that might have shown up overnight.

[nev_payne]

Sorted out the nasty ground - turns out the bolt I replaced the OS ground bolt with (lost down the subframe during rebuild) was painted and this utter crap for earthing anything. Only reason it was working was most likely the copper in the grease it was caked in.

Replaced with clean shiney new one and a cleaned up earth cable clip, and the engine's happy happy.

Initial check over for engine oil leaks has come up empty - not a drop to be seen, and all is fine and dandy in sump hovvel.

Ordered some more parts today including:

- The exterior temperature sensor accessory kit
- Diamond white Knightsbridge coach line set
- New MPI engine bay fusable link box with connections and starter cable.
- New engine ground cable (current ones not all that shiney anymore and beginning to splay out).

Stay tuned!

Edited by nev_payne, 01 May 2012 - 08:37 PM.

[twistedtorment]

Its awesome you got him back on the road again! after some of your posts i was expecting him to be in the for sale section lol well done!!

[nev_payne]

Ha you must have gone through the entire project, that must have been quite a read.

Thanks, and yeah there were a few points I just gave up. All worth it in the end, and now look at him. Stunning.

[nev_payne]

Can't wait to get over to page 17 on this project - the engine build photos are making a bandwidth killing.

Anyway - presents arrived! Arch protectors, Knighty pin stripe, and the hen's teeth fusable link box.



More on the way hopefully.

[bcjames]

A new-in-box fusebox