850-R Engine Rebuild - Pic Heavy

[woody]

Hi all.

Just thought I'd share my progress of rebuilding an engine to pop into my '96 850-R.

It started last year whilst I was in Afghanistan when I had a phone call saying my wife was stranded after my cambelt failed (Doh, school boy error I know)

I had the car recovered from RAF Marham to Russell's (RT Mechanics). Although the belt failed at 20 mph, it had around 8 damaged valves and corresponding marks on the pistons. I thought it time to get it overhauled. I got the head re-furbed and thought it about time to get my hands dirty and complete the rest of the refurb myself! lol

12519
The head after refurb.

12520
I sourced an engine that was beleived to be refurbed but no to the extent that it could take more bang!

12521
I sourced some THS rods, so I set about removing the head etc to enable fitment.

12522
Initial signs were good with evidence of a recent honing.

12523
I was extremely pleased with the condition of the crank.

So long story short. I bought new big end bearings and new rings from Rufe (Cheers Rufe) I sized the rings in the bores only to find that the standard volvo ring gaps were too big and as the pistons were standard size (D) alarm bells started to ring! So I did a trial fit of the pistons and THS rods only to find they fouled the base of the liners! THS instructions did warn this was a possibility. Enough was enough. I sent the block to MJ Engines Services in Westbury and asked them to give the block a good once over. Around 1 week later they contacted me to say that machining the base of the liners to enable rod rotation was not an issue, but the main issue was that the engine was, on average, 5 thou oversize! Bugger. They did say however that the crank was fine and just needed a polish. They said that an 81.5mm rebore may be ok but said an 82mm rebore would make sure the bores were straight and true. I purchased a set of 82mm Wiseco pistons and packed them off to Simon at MJ Engines. I stated that I was in no rush and a few weeks later I collected my refurded block with the internals inserted.

12524
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12526

More next time.........

[theflyingbrick]

nice,very nice :)

[Dangerous Dave]

Awesome mate, great pics, looking forward to seeing the next part of the build.

[smithy]

nice build mate i have wisco pistons in my 940 nice pistons they are

[Volvostorm]

I have Wisco's in mine too, the build is looking really nice too :)

[JUDGENINJA]

Are you going to be doing anything special? Anything done to the valves, crank,flywheel??

[Wobbly Dave]

who did your head refurb?

[woody]

Are you going to be doing anything special? Anything done to the valves, crank,flywheel??

TBH, I've had a gut full of this project and it has gone further than planned! Hind sight is a wonderful thing! As long as it’s a smooth runner, I'm not planning on setting any records with it. Crank, Valves & Flywheel are standard. At least it'll be strong enough for me to tweak in the future, if I so wish.

Dave, RT got my head done for me and they did a top job.

More pics to follow tonight.

[woody]

Thanks for all your positive replies. I'm low on 'Positive' with this at the moment, but the finish line is in sight! lol

[p fandango]

I'm low on 'Positive' with this at the moment
i'm not surprised, i've seen the price of the Wiseco pistons lol. As you say should be strong enough to handle anything now

[woody]

12528
THS Rods & ARP bolts.

12529
Was strongly advised to fit a new oil pump and bought a new water pump too. Cheers again Rufe.

12530
Block was originally painted black. I wasn't a fan, so it went back to silver.

12531

12532
First coat.

12533

12534

12535

[woody]

12536
Ready to fit Water Pump.

12537

12538
Fitted

12539
Oil pickup tube fitted. When to engine was initially dismantled, the strainer was full of silicone sealant worms!

12540
New 'O' Rings fitted. When sump was initilally removed, these were absent! Just loads of silicone sealant!

12541
Oil Pump gasket in place ready to take the pump.

12542
Oil pump fitted. Temp bolts fitted for now.

12543
Decided to get a new set of Head Bolts. As you can see, the old bolt on the right has stretched ever so slightly!

[woody]

12544
Applying sealant with small foam roller that I got from an online craft shop!

12545
Sealant was applied with the foam roller, but I couldn't resist putting another small ring of sealant on top!

12546
All tightened up.

12547
All tightened up.

12548
Another view

12549
I couldn't resist popping the head on to see what it will look like after it's fitted properly!

12550
Time to strip the refurbished head ready for fitment.

12551
New head gasket in place.

[Jamest5r]

Hello mate long time no hear glad its all going well :)

[woody]

12552
Showing the quality of the skimmed face.To enable this photo to be taken, the head had to be man-handled about and during which particles of blasting media were found. I thought it best to wash the head in a hot chemical bath just to be safe.

12553
Head was washed in every position to make sure no crevise was missed.

12554
It didn't take long to dry as it was pretty hot!

12555
Head in position. 2 head bolts added to prevent any costly mishaps!

12556
Front view.

12557
Top view.

12558
The final 130deg!

12559
Torqued.

[woody]

Hello mate long time no hear glad its all going well :)

Hi James. Yeh been a little busy in life lately. Must crack on with this now as I'm posted to Marham in April! How's you buddy?

[woody]

12560
With the car now undercover, progress can now continue. PCV system in position.

12561
Main water pipe temporarily fitted as waiting for a small paper gasket I forgot to order! Doh

12562
Thermostat housing top being squared up on surface table

12563
Nice and true

12564
Thermostat top and body all squared up and fitted

12565
Inside ready for engine removal

12566
The old block

12567
Nearly ready for the lift. Must give max credit to Alex. Thanks mate.

[the young mechanic]

well done

[Volvostorm]

Looking at these pictures brings back many memories!

[Jamest5r]

Hi James. Yeh been a little busy in life lately. Must crack on with this now as I'm posted to Marham in April! How's you buddy?


Yeah good cheers mate, you will be well at home at Marham 3 members from here posted there including Mr Moose and also a track day there in a couple of months so should get to meet :)

[woody]

Yeah good cheers mate, you will be well at home at Marham 3 members from here posted there including Mr Moose and also a track day there in a couple of months so should get to meet :)

Champion. Providing the engine settles in ok, she'll be there, if not the Clio will be! lol

[smithson007]

Good write up mate. Engine should be good for a good bit of power when your finished.

[woody]

Good write up mate. Engine should be good for a good bit of power when your finished.

Thanks very much. I'll just be glad to her running again.

[woody]

12568
And relax.........

12569
Another view

12570
Gearbox is around 12 months old after I had it converted by Russ @ RT from an auto. Yes I know it would have been cheaper and easier to buy an 850-R Manual but that would be boring! haha

12571
Turbo and Manifold will be removed soon. I have an ME7 manifold to fit.

12572
Pulling Pulley Damper off.

12573
More progress with new engine. Soon be time to fit the Cams etc

12574
Block removed

12575
It's been a good companion over the years. We stripped the block to weight it in. For a block that had around 200k on the clock, there was very little wear on the bearings and only minor scores on the crank. I'm retaining the crank as I plan to make a decorative lamp out of it in its memory!

[The Flying Moose]

Well Woody a thoroughly good job so far so I see. Its nice to see projects at this level and also to see that its being done properly with no expense spared... a real labour of love!

I look forward to seeing it when you arrive at Marham!

[Kerry_T-5R]

Nice work, would like to build an engine for mine one day..

Cheers

Kerry

[woody]

Nice work, would like to build an engine for mine one day..

Cheers

Kerry

Cheers Kerry. I've been very lucky as I've been able to use excellent facilities.

[woody]

12586
More parts removed, cleaned and refitted.

12587
Time for a lunchtime steam clean

12588
Much better

12589

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12591
Sealant applied to cylinder head prior to cams and carrier being fitted. Sealant requires a little sponge rolling first.

12592
Rolling complete

12593
Cams secured into place with wire until carrier is bolted down firmly.

[woody]

12594
Home made cam locking tool kindly lent to me by Niles, being held in place by tape. Looks crude but it did the trick. Cheers Andrew.

12595
Secured.

12596
Cam sprockets loosely fitted.

12597

12598
Pin pulled on tensioner. Careful rotation by hand has revealed no contact. Don't pay any attention to the tipex marks!

12599
All covered up

12600
Couldn't resist putting my TWR plug cover on for a photo!

12601
Flywheel and Clutch fitted. Engine stabiliser and Cam position Sensor fitted

[woody]

12602
Slotted in surprisingly easy.

12603

[M-R-P]

Lovin' this thread mate ;)

[woody]

12604
Manifold and Turbo removed

12605
Original Pre-ME7 Manifold is at the top and the later ME7 Manifold below it. Note the difference in the openings!

12606
Cracks in old Manifold

12607
ME7 Manifold before an attempt at Gas Flowing!

12608
After. Bit more to go yet!

12609

12610
Original Turbo looking at compressor wheel. For 200,000 miles there's not much play at all.

12611
Turbo after cleaning, with Forge blanking plate fitted.

[Wobbly Dave]

Might sound a silly question but with all this effort why are you staying with the 15G?

[woody]

Simples, Money! I'm close to moving house and a posting so I just need her back into her load-lugging role soonest. Once it's settled, then I can move forward.

[Wobbly Dave]

Actually - I figured as much - as it is the only reason for not swapping with everything in pieces so to speak.

i have been following this build with a keen eye. I am just wondering how much I can do myself on my own build project.

[Volvostorm]

Actually - I figured as much - as it is the only reason for not swapping with everything in pieces so to speak.

i have been following this build with a keen eye. I am just wondering how much I can do myself on my own build project.

Apart from machining that might be needed, rebuilding the engine is fairly simple, just follow a Haynes :)

[Wobbly Dave]

So do you know any decent ones given that you've already been through this process Paul?

[Volvostorm]

So do you know any decent ones given that you've already been through this process Paul?

Decent what mate?

Machine shops?

[Wobbly Dave]

Yes in Shropshire - I don't really want to have to run around the earth looking for someone to do the boring work - LOL

[woody]

Like you said Dave, distance is a factor. TBH I found the machine shop I used via a Westfield/Caterham7 forum who recommended them! I went to drop my block off and it was one of those machine shops you don't see much of anymore. It had character with nothing too shiny and had random cups of tea dotted about, engines everywhere in differing stages of build and the lads were wearing Fred Dibnah styled oil stained woolly hats lol

[Volvostorm]

Yes in Shropshire - I don't really want to have to run around the earth looking for someone to do the boring work - LOL

The best one I know is in Wem

http://www.motorcast.com/

[woody]

12636
CV Boots, Caliper Carrier Bolts and water gasket received. Cheers Rufe. Time for another late night soon.

[Dangerous Dave]

Yes in Shropshire - I don't really want to have to run around the earth looking for someone to do the boring work - LOL
I found a cylinder head place in Bilston, couple of old engineers there so felt better when I dropped it off. The quality of the skim was beautiful. Not sure what other services they provided though. Head skim cost me £25

http://i150.photobucket.com/albums/s101/bomb192uk/08122009247.jpg

[woody]

Lovely finish. I read an article recently where the author said to key-in the service of freshly skimmed head with an abrasive paper/cloth to let the gasket grip. I could see what he meant but I haven't followed suit.

Anyone else heard this before?

[Slackey]

Looking good Woody, shame I ma not at Lyneham I would have enjoyed getting my hands dirty on this one!


I'm retaining the crank as I plan to make a decorative lamp out of it in its memory!

This bit worries me............... I taught you electrics! lol

[Dangerous Dave]

Looking good Woody, shame I ma not at Lyneham I would have enjoyed getting my hands dirty on this one!



This bit worries me............... I taught you electrics! lol

Welcome to the forum!

[woody]

This bit worries me............... I taught you electrics! lol

Don't flatter yourself Slackey, you only taught us 'Heavies' DC Electrics :D

Welcome by the way mate. Have you had an Ovlov in the past? I thought you were a Ducati man!

[woody]

12647
1st boot on.

12648
CV Boots done. Cheers Drew.

12649
ME7 Manifold fitted.

[Jamest5r]

Looking spot on is this build mate your making it look easy lol :)

[Slackey]

Don't flatter yourself Slackey, you only taught us 'Heavies' DC Electrics :D

Welcome by the way mate. Have you had an Ovlov in the past? I thought you were a Ducati man!

I have still got one Woody, there are some pics in my introduction post >>>Intro<<< (http://www.vpcuk.org/forums/showthread.php?t=41182)

Hey when I taught you that electrical phase I taught you all I knew....... thats why it took less than a week! :uglyhamme

And as for the Duke....... I could not resist a pic...

[woody]

12660
Turbo fitted.

12661

Before I packed up for the day, I tried a test fit of the heat shields and their springs. Well what can I say! I was in biff mode and even emails to Russ couldn't set them straight in my head. Luckily Google images came to my rescue. All in all, what a mad set-up!

I'll post pics of the Turbo area complete tomorrow.

[daza-b]

cracking write up mate, im gonna be following this closely, soon be me doin this! lol just a question, what was that tool you used to torque up the head, really interested me that, also fancy doin a step by step guide for me on the rebuild ;) haha

[woody]

cracking write up mate, im gonna be following this closely, soon be me doin this! lol just a question, what was that tool you used to torque up the head, really interested me that, also fancy doin a step by step guide for me on the rebuild ;) haha


Cheers Daz. The tool I used was called a 'Torque Angle Dial Indicator'. It's not an exact science but it enables you to turn the head bolts 130deg on the third and final stage. The item on the flexi attachment is a magnet which wasn't much use on an Alloy head! There are other types that use locking bars and these are better. Top tip though. Before you install the new stretch bolts, make sure the underside of the bolt head is lubricated. This will prevent the ominous cracking sound and make the 130deg turn easier to perform.

With reference to a step-by-step guide, 'NO' lol. Serious though, I'm no expert and my engine hasn't started yet!!!! Everything I've learnt has been gleaned from this cracking site and trawling Google/Images! If you need any advice though, I'll help where I can.

Good luck and remember, it's fun and extremely satisfying!

[daza-b]

Cheers Daz. The tool I used was called a 'Torque Angle Dial Indicator'. It's not an exact science but it enables you to turn the head bolts 130deg on the third and final stage. The item on the flexi attachment is a magnet which wasn't much use on an Alloy head! There are other types that use locking bars and these are better. Top tip though. Before you install the new stretch bolts, make sure the underside of the bolt head is lubricated. This will prevent the ominous cracking sound and make the 130deg turn easier to perform.

With reference to a step-by-step guide, 'NO' lol. Serious though, I'm no expert and my engine hasn't started yet!!!! Everything I've learnt has been gleaned from this cracking site and trawling Google/Images! If you need any advice though, I'll help where I can.

Good luck and remember, it's fun and extremely satisfying!

cheers bud got one of them on order now, also subscribing to this thread so can keep an eye, good luck on the rest of its and if you get stuck with anything ill help where i can :)

[woody]

12663
Another night done. Turbo plumbed in.

12664
Turbo oil and water pipes plumbed in.

12665
Ready to lift

12666

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[woody]

12699
All lined up!

12700
Nearly home

12701

12702
And, Relax!

12703

12704

12705
Nearly done

12706
IPD filter being fitted. I was quite impressed with the quality of this product. I had trouble getting enough slack in the MAF Cable, so i decided to re-route the main loom a little and mangaed to get enough slack for it not to be like a piano string!

[daza-b]

looking promising mate, are u at an army barracks? i wish i had all the ramps and stuff, im doing all work on the floor lol

[woody]

looking promising mate, are u at an army barracks? i wish i had all the ramps and stuff, im doing all work on the floor lol

I'm very fortunate to be at RAF Lyneham and it's the hangar I work in. Lunch times and late nights! Had to get a move on with this project as after April, we are out of here! We are some of the few left to close the hangar. End of an era.

[daza-b]

good luck with it buddy :)

[Jamest5r]

Loving that little mobile lift, mod selling the stuff off when they close it?

[woody]

Loving that little mobile lift, mod selling the stuff off when they close it?

Afraid not, it all goes to other Station and Units.

[martybelfastt5]

looking good

[woody]

12708
God I hope all this effort is worth it! Still need a set of plugs but at least I can give her a spin over this week and get fluids moving. Talk about nervous! :scared:

[daza-b]

im nervous and excited for ya lmao!

[Niles]

Dear Mr Woody. Im so happy for you. great job done!!! Best of luck on start up! Im sure it will be 110% fine!!!

[Wobbly Dave]

I put some new plugs in Betsy on Sunday - makes a big difference, even though the ones coming out were perfect in colour.

Good job - guess it helps a lot having a hangar to work in?

[woody]

http://www.youtube.com/watch?v=WWxNBPjd5UM

First crank was brilliant. Getting plugs tomorrow; thought there was a set in the boot but I was mistaken!

Oil pressure light went out after 5 secs and remained off for around 25 secs after cranking ceased.

Happy so far. Big day tomorrow!

[smithson007]

Nearly there mate. Youve made all this look very easy. lol

[Volvostorm]

I'm hoping to get mine doing that this weekend!

Sounds well mate :)

[woody]

I'll be chuffed to bits when she's up to temp with no leaks!

[smithson007]

Nice to see another one being saved from the breakers yard.

[Jim S70R]

Great stuff and well done on your build so far, I bet your itching to drive the old girl again.

[woody]

http://www.youtube.com/watch?v=BpUYkQ_7nTY

Hello all. Well, here it is! Very noisy to begin with and all quietened down except for one follower! Started it again this morning from cold and all was quiet! The troublesome follower then raised its ugly head again but it's more intermittent now!

Its MOT is booked for Friday, so I'll see how it is after a 30 mile drive. If that doesn't work, it'll be Flushing Oil time and that doesn't work, it'll be cams out again! Arrggghhhhhh.

Fingers crossed!

[martybelfastt5]

fingers crossed

[Volvostorm]

Bar the follower, it sounds sweet :)

Bet your pleased

[Jamest5r]

Nice work mate always good when they start :), mine ran like a 3 legged dog for the 1st couple of mins till the oil pressure had built up around the top half, im sure the follower will quieten down :)

[woody]

Thanks all.

She's had about an hour running time so far and still not perfect. I'm not getting too excited untill after the MOT on Friday.

[woody]

http://www.youtube.com/watch?v=IyIW9sH4_eI

At last, the hydraulic followers finally quietened down! Huge sigh of relief!

MOT in the morning!

[Volvostorm]

Now that sounds really nice!

[woody]

All I can say, it's a relief! lol

[Jamest5r]

http://www.youtube.com/watch?v=IyIW9sH4_eI

At last, the hydraulic followers finally quietened down! Huge sigh of relief!

MOT in the morning!

Told you :) just make sure you drop the oil and replace as soon as you can now only cos you've had a rebore and you never know what tiny bits are still around after 1st cranking.

[woody]

Told you :) just make sure you drop the oil and replace as soon as you can now only cos you've had a rebore and you never know what tiny bits are still around after 1st cranking.

MOT passed!

Time to settle her in now.

Cheers James. I'll prob do it next week as I've got a nice pot of Mobile1 to go in!
On the ramp this morn, I noticed that I've a minor drip from around where the oil cooler pipes leave the block. I fitted a new 'O' ring, so I'll leave the belly pan off for a while and keep an eye on it.

[woody]

Hello all,

Just a quick update.

Checked underneath the car yesterday and everything is bone dry, so very happy with that.

So I'd just like to say a huge thank you to the following for guiding me through this project.

TBH, I've had a lot of help with this, so credit where it's due. Cheers guys; Alex, Andrew(Niles), Drew, Russ(RT), Simon(MJ Engines), Rufe and not forgetting you guys here on the one and only VPCUK! :beer:

I look back on it all now, and they are quite simple engines after all!

I'm happy to give advice to anyone who needs it. :B_thumb:

[Volvostorm]

Thats great news mate :)

I can't wait to get mine started, spinning her on the key is huge buzz for me :)

[woody]

Thats great news mate :)

I can't wait to get mine started, spinning her on the key is huge buzz for me :)

Cheers mate.

Have you much to do Paul?

[woody]

Just a quick update guys.

12799

12800

Well I guess that's it for now! Just sprayed the intercooler pipe with Chrome Spray.

250 Miles under her belt now and no issues.

[daza-b]

Just a quick update guys.

12799

12800

Well I guess that's it for now! Just sprayed the intercooler pipe with Chrome Spray.

250 Miles under her belt now and no issues.

im not jealous...honest! lol looks really good matey! that cold air intake, who made that? i want one! lol

[smithson007]

What do you think of the T-bar clamps youre using on you intercooler pipework?
Are they much better than normal jubilee clips?

[woody]

im not jealous...honest! lol looks really good matey! that cold air intake, who made that? i want one! lol

Thanks Daz. That Chrome pipe is from Volvo! It's the piping off an early T5, c.1994. Rufe from FRF ordered it from Sweden for me. It came painted black so I stripped it and sprayed it up.

Not sure on cost mind. Don't think it was that expensive and tbh, it's quite crudely made!

If you mean the air filter, it's an IPD jobby from the USA.

[woody]

What do you think of the T-bar clamps youre using on you intercooler pipework?
Are they much better than normal jubilee clips?

Yes. I used to have one Jubilee clamp at each join and I managed to blow one clean off 2 years back!

They are not perfect as they may be too big as the clamp has no more travel left. I'll see when I run her at full rpm to see if they hold!

I got a pack of ten Stainless T-bar Clamps from fleabay for £21.

[woody]

What do you think of the T-bar clamps youre using on you intercooler pipework?
Are they much better than normal jubilee clips?
Hello buddy, just an update on the T-Bar clamps, no issues at all with them.