As promised I spend last week on the project...
Basically I took the head off - and put it aside as it had been rebuilt 2 000 miles ago. Unbolted manifold and chucked it out.... next was oilpan , oilpump and timing belt, pulleys etc. First thing was to check rod bearings and as expected the ones on cyl 1 & 2 (nearest to the cam wheel) showed some sign of wear > nothing to worry about but worn. Could have been my aggressive cornering with low oil level or just mileage ( my car has been through 180 000 miles) it was the same case with crank bearings where my friends at the garage i am doing all this suggested they are ok , but i insisted to be changed. I opted for Mahle G60 spec bering as they are from stronger material. I changed pitons as well (no wear on cyl walls whatsoever... a bit of the factory honing was missing, that is all) . original pistons were 80'98 mm , the forged ones i ordered are 81'00mm , the "key" on the rings is 0.03mm. I has become a very tightish but perfect fit and would require some gentle running in.
Head was put back on - used a G60 spec twin layer headgasket - fits straightaway and I hope it holds up to 1 bar....
Unfortunately the custom manifold was not ready as before the head was taken off we had to take last measurements and had to be welded as I was rebuilding the engine. It would be ready by the end of this week.
I went to the local breakyard and bought MK4 fuel rail and oil line for the turbo - they will both need some modification to fit properly. There are 2 types of fuel rails for 1.8 engines - round pipe and square pipe ones... i bought the round type and will have to change the way it bolts to manifold ( nothing in common there) and both feed and return lines... it has been measured and will be done. I also made fittings to plug the manifold holes and made beds for the top fed injectors - easy.
The IC i am using did not fit properly ( nothing ever works as planned
) adn required the rad to be moved up and back towards the engine...still did not clear and will need modification of the front beam ( the one that holds the engine mount) I am going to lower it about 1/2 inch and raise eng mount the same.....
I had to leave for macedonia on Saturday (urgent issues) , and I am back at work - so will have to work at nights weekends to complete this .... There is not much left to do - pipework to and from turbo ( i friend of mine needs 3-4 hour to do it - need turbo return line for oil) ... and exhaust ... i am to drive it for at least 1 000 miles NA (i.e turbo on but no boost) as i want to run engine in and re - tighten the head . And I don't want to play with mixtures and advance on a tight engine
Then I will change to G60 management and the bigger injectors ......
I have pics on my D 600 and will post later
