850-R Engine Rebuild - Pic Heavy

[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]

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

Attachment 12569
Another view

Attachment 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

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

Attachment 12572
Pulling Pulley Damper off.

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

Attachment 12574
Block removed

Attachment 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]

Attachment 12586
More parts removed, cleaned and refitted.

Attachment 12587
Time for a lunchtime steam clean

Attachment 12588
Much better

Attachment 12589

Attachment 12590

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

Attachment 12592
Rolling complete

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

[woody]

Attachment 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.

Attachment 12595
Secured.

Attachment 12596
Cam sprockets loosely fitted.

Attachment 12597

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

Attachment 12599
All covered up

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

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

[woody]

Attachment 12602
Slotted in surprisingly easy.

Attachment 12603

[M-R-P]

Lovin' this thread mate

[woody]

Attachment 12604
Manifold and Turbo removed

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

Attachment 12606
Cracks in old Manifold

Attachment 12607
ME7 Manifold before an attempt at Gas Flowing!

Attachment 12608
After. Bit more to go yet!

Attachment 12609

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

Attachment 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