850-R Engine Rebuild - Pic Heavy

**woody** · Tuesday 7th February 2012, 21:16

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.........

**theflyingbrick** · Tuesday 7th February 2012, 21:24

nice,very nice

**Dangerous Dave** · Tuesday 7th February 2012, 21:25

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

**smithy** · Tuesday 7th February 2012, 21:36

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

**Volvostorm** · Tuesday 7th February 2012, 21:50

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

**JUDGENINJA** · Tuesday 7th February 2012, 22:08

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

**Wobbly Dave** · Tuesday 7th February 2012, 22:52

who did your head refurb?

**woody** · Wednesday 8th February 2012, 11:41

Originally Posted by JUDGENINJA

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** · Wednesday 8th February 2012, 11:47

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** · Wednesday 8th February 2012, 12:10

Originally Posted by woody

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** · Wednesday 8th February 2012, 18:27

Attachment 12528
THS Rods & ARP bolts.

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

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

Attachment 12531

Attachment 12532
First coat.

Attachment 12533

Attachment 12534

Attachment 12535

**woody** · Wednesday 8th February 2012, 18:57

Attachment 12536
Ready to fit Water Pump.

Attachment 12537

Attachment 12538
Fitted

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

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

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

Attachment 12542
Oil pump fitted. Temp bolts fitted for now.

Attachment 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** · Wednesday 8th February 2012, 19:13

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

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

Attachment 12546
All tightened up.

Attachment 12547
All tightened up.

Attachment 12548
Another view

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

Attachment 12550
Time to strip the refurbished head ready for fitment.

Attachment 12551
New head gasket in place.

**Jamest5r** · Wednesday 8th February 2012, 19:15

Hello mate long time no hear glad its all going well

**woody** · Wednesday 8th February 2012, 19:24

Attachment 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.

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

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

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

Attachment 12556
Front view.

Attachment 12557
Top view.

Attachment 12558
The final 130deg!

Attachment 12559
Torqued.

**woody** · Wednesday 8th February 2012, 19:26

Originally Posted by Jamest5r

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** · Wednesday 8th February 2012, 19:49

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

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

Attachment 12562
Thermostat housing top being squared up on surface table

Attachment 12563
Nice and true

Attachment 12564
Thermostat top and body all squared up and fitted

Attachment 12565
Inside ready for engine removal

Attachment 12566
The old block

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

**the young mechanic** · Wednesday 8th February 2012, 19:57

well done

**Volvostorm** · Wednesday 8th February 2012, 20:06

Looking at these pictures brings back many memories!

**Jamest5r** · Wednesday 8th February 2012, 20:19

Originally Posted by woody

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