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
Attachment 12519
The head after refurb.
Attachment 12520
I sourced an engine that was beleived to be refurbed but no to the extent that it could take more bang!
Attachment 12521
I sourced some THS rods, so I set about removing the head etc to enable fitment.
Attachment 12522
Initial signs were good with evidence of a recent honing.
Attachment 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.
Attachment 12524
Attachment 12525
Attachment 12526
More next time.........
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