finally started on my 2.5 turbo project now engine complete

[hass]

hi guys

finally started the long waited turbo project
got most parts togeather

low comp engine
decomp plate
42 lb injectors
exhaust manifold
t34 turbo
volvo intercooler











just a few bits need now
intercooler pipes
actuator for my turbo
oil feed pipes
head set
non streech head bolts



started work on my engine
keeping it standard but rebuilding it

engine work starts

strip block to bear shell

check crank for any damages ie if its been scored


started to rehone the bores


cylinders 1,2,3 been rehoned.cylider 4 need couple of more goes



that should do it.



right once all bores were honed smired the bores in oil so they dont rust up

then was the job of cleaning the pistons



as you can see the pistons are filthy


three down three to go



now all six pistons are clean
using the old piston rings i cleaned the grooves where the ring sit in the piston

next set is to clean and paint the block
will get some more pictures and keep you guys up to date

thanks hass

[Ant]

Nice work so far dude

Dont forget to email/PM fozzy for the bolts, 160 mm remember !!

[SPADGE]

I would bin the Volvo i/c with its plastic end tanks having seen what happened to MattG's at the weekend

[Ant]

NOS backfire Spadge, Volvo IC is up to 20 psi no worries, Matt's had had few clouts prior to the pod too.

[hass]

thanks ant

spoke to fozzy monster
and ordered my bolts

thay should be with me 2/3 days

[hass]

right cleaned up the block
and started to mask it up








first coat of vht paint goes on



then the second and third and paint runs out
will get some more tomorrow
and give it couple of more coats

any way....

i thought i might aswell strip the head
so i did


nice set of rockers
not even worn well only slightly


even the cam looks great


out with all the valves
and a nice bare head ready tobe set of to be skimmed and pressure tested




valves need to be cleaned


ahh what the hell might aswell do them too..


so guys so far so good
gonna call it a nite now,will keep you lot informed on the progress

tomorrow i will give the block couple of more coats of paint
and send the head off.

thanks hass

[e30_Turbo]

Looking good dude

[hass]

thanks fozzymonster

[SPADGE]

NOS backfire Spadge, Volvo IC is up to 20 psi no worries, Matt's had had few clouts prior to the pod too.

Ahhh i see! I stand corrected cheers Ant

Hass it looks like your doing a tidy job there mate keep up the good work!

[Demlotcrew]

After seeing the Ebay manifolds im quite impressed and its a right shame about all the bad press they have had!

Good choice!

[blingsta]

Hass, i think you should go 1 step further and while the heads off put a turbo cam on ! more ponies!

[1an]

After seeing the Ebay manifolds im quite impressed and its a right shame about all the bad press they have had!

Good choice!

Andrew, dont want to start an arguement. if these are the same as the one that Ant showed me when i was down his place the other month then i wouldnt be putting it near my car, cant exactly recall waht he said but it wasnt to good to be honest.

[mattG]

Hi Hass, looking good,
Here's a couple of pics of whats left of my intercooler . It had been fine for several months and never leaked even with several hard clouts from speed bumps I plan on fitting my next intercooler a bit higher by modifing the front x-member.
Why I got a NOS back fire at the pod I not to sure! may be turning the engine on & off while queuing for 1/4 gutted wanted to show those M30 guys FI is the way

[mattG]

Hi Hass, looking good,
Here's a couple of pics of whats left of my intercooler . It had been fine for several months and never leaked even with several hard clouts from speed bumps I plan on fitting my next intercooler a bit higher by modifing the front x-member.
Why I got a NOS back fire at the pod I not to sure! may be turning the engine on & off while queuing for 1/4 gutted wanted to show those M30 guys FI is the way

[E30BeemerLad]

There are some cheap manifolds on the jap scene, often from China. The general concensus is that they are oK quality, but it is usually adviseable to add some extra bracing to hold the weight of the turbo as they have been known to snap

Nice project dude, good to see someone getting stuck in. Keep the pics coming

[Kos]

After seeing the Ebay manifolds im quite impressed and its a right shame about all the bad press they have had!

Good choice!

Andrew, dont want to start an arguement. if these are the same as the one that Ant showed me when i was down his place the other month then i wouldnt be putting it near my car, cant exactly recall waht he said but it wasnt to good to be honest.

for the money they cost they are very very good, i've been up close to one and in my opinion they are up to the job.

the one thing i'll say is make sure you check all the studs in the head as they are known to break abs shear off causing damage to the head, the added weight of the turbo will not do them any favours.

[Ant]

To clarify a bit here.....

there are 3 know "versions" of that manifold design.

one is sold as the ITG manifold, typically £400 or so from Ebay and made from 2.5 mm wall thickness stainless, that one is OK with some extra bracing as per Kos's post above

The "real" manifold is sold through many outlets in the USA, often re-branded but its the Extreme performance inc and is usually branded as such, these are £720 with import and VAT and are 3.5mm wall thickness with thicker head flanges and more porting to the collectors, generally better radius on the bends too, these are Quality and the price reflects this.

the 3rd version is simply shite, made from "stainless" with wall thickness as thin as 1.2mm in places( remember the bends are thinner on the outside radius side! ) gas welded together with thin welds with low penetraction etc etc.

Simply put, the 3rd is one to avoid and is indeed the one in my unit, it currently serves as a door handle to my office and thats the best place for it, sooooooo thin in places you can actually bend it with your fingers !

The other two are OK, the £Â£Ã‚£ one is obv the best, but the ITG will do the job nicely indeed with the addition of some bracing, All should be heatwrapped to increase the efficicncy of the final setup, helps with overall strength too.

@ Hass, I assume you've changed the core plugs dude ???? False economy if you haven't yet dude

[hass]

i know that the manifolds a shabby one but im sure if i was to reinforce it it'll be ok

the only way is trial and error

anyway back to the engine
heads been sent off to be skimed and tested

so i thought ill build the block up...
main bearings are wrong, focker
so i decied to do the piston rings

hopefully ill be on the phone to euros tomorrow and get the right ones
and start to finish the block off
its gonna need a few more coats of vht paint so ill post some up tomorow evening
along with hopefully a finished block and maybe head (if i get it back 2morrow)

anyways thanks for all the positive feed back

hass

[hass]

hi ant should i change the core plugs????

they look like there in good shape
or do i have to do them in order with the turbo project

[Demlotcrew]

Unless you are expecting to have headgasket leaks then i would leave them alone.

I know where you can get oversized head gaskets if thats any use to you?

Ive seen the cheapo ebay manifold and i can assure everyone thats its a good quality item with good welds and as been stated can do with some bracing of the turbo but for the money you cant go wrong! All primary lengths the same, polished stainless and good thick flanges with decent welds. Show me anything that can get close?

[hass]

thanks demlotcrew but im gonna use a normal headgasket
ive bought a decomp plate which is 3mm already
i think an overseized H/G will be too much

[hass]

quite a lot done dis evening

got the head back from the engineerers
got my new set of main bearing
finished the block
put all my piston ring
big ends
main bearings
oil pump
and front and rear oil seals

and the head
relapped all the valves
put camshaft in
oil stem seals
rockers
rocker shafts
and front oil seal

so were getting some where
was gonna post some pics
but its 12.30am
and i just got back home from the garage from 8.30 this morning
so im a bit tyred

but will post pics tomorrow

[isTURBO]

Hi Hass

A spectacular job mate. keep them coming.

congrats

[hass]

hi as i said in my last post here some of the picies

head back from engineerers


first few coats of black vht paint


started to piece the piston rings togeather
while head drys



main bearings in place



crankshaft in



removed the old rear engine oil seal (crankshaft seal)


nice new seal put on


and fitted..


didnt take pic ov the front two oil seals but they were done too

right back to the head


exhaust valves all lapped in



now for the inlet

ahh last of the valves. i fecking hate lappin valves


new set of oil stem seals were fitted

some of my valve springs]


then put cam in then all the rocker shafrts and rockers
havent adjusted the tappets yet but will do after
new front oil seal on the cam
and the thin one that goes around the oil seal housing


back to the block got all pistons in and fitted my new big end bearings
fitted new oil pump too

and the block is sort of done




sprayed the timing covers silver vht paint


and also the rocker cover got a coat of paint but will need sevral more
and also the inlet manifold


just some shots of the head with the manifold and turbo






right thats it for now guys
hopefully i get my head bolts tomorrow so i can finish the engine off

still got loads to go but ill try and keep you lot posted each step

thanks for the advice ant and erol
and thanks for the seal erol

thanks hass

[e36_koz]

looks lovely mate is it a diesel engine and on one of the pictures is that you thumb. F**K thats a big Thumb

only joking mate engine looks sweet guys i have seen it in real life and it looks so sexy.

good luck hass

[hass]

ur just jealous coz ive got man hand not girly ones like

anyway thanks koz

[hass]

hi everyone a bit more progress

head bolts arrived this morning thanks mark (fozzymonster)
so the head can go on

put plenty of sealer on the decom plate

and quickly cleaned the threads in my block and whacked the head on



torged the head down to 80lbpsf and put my water pump tensioner and standard timing belt





sprayed up my timing covers and bottom pulleys and fitted them







sprayed the sump but not gonna fit till i sort out the oil return


few pics of my engine with inlet manifold still need few more coats






pictures with inlet and exhaust and turbo but nothings bolted up yet



so the engine is done just a few things like making brakets to strenghtin the manifold
oil feed and return
and little bit and bobs then engine can go in

the next thing to do is mount my intercooler
and get the custom exhaust done

thanks hass

[blingsta]

moving along nicely Hass !! im off Mon and Tues. i'll pop by to give you a hand mate..

[e30_Turbo]

Glad they made it ok

Mark.

[zimm_zimmer]

man i wanna do this, is this the engine out of your car or a spare you bought, i wanna get a nackered engine and do it up but uprate it then turbo it, which turbo you using and is it going to go under the bonnet being that high up, you say you need to strengthen the manifold is that because its not meant for the strain of the turbo?? thanks

[fowler]

the turbo is in correct position as all 6 branch turbo manifolds sit the turbo ever so slightly higher.
Hass make suer the bracket for the manifold is strong enough when hot as it will lean right over.
Use the m6 stud near original washer bottle position as it is in a perfect position.
Also you will have to lose the large part of the washer bottle as turbo will melt it. but keep the intense wash bottle as you need one for MOT.
regards
Ben

[Ant]

@ Hass, you tried fitting the oil cooler take off plate yet ?

my bet is ot wont fit dude, the unit and filter should bolt up( just) but the oil in/out pipes will foul the lower parts of the collector.

No heat wrap either ! thats not gonna help efficiency much dude.

[fowler]

Ant he needs one of you relocation kits !!!!!!!!!!!!!

[hass]

yea ant tried to fit the oil filter housing it goes on but i have to clock the unit so the oil filter faces the front of the engine
but havent tried the pipes might be ok but untill i try i wont know

also the maniflods just on to see how it looks and to make the brakets
but will get heat rapped!!

fowler im making some brakets to go under the manifold and bolt up to the block
also im gonna make a braket from the inlet maniflod right up to the turbo
hopefully that should sort of hold things in place

and i have to strenghen the manifold cos its ok but not great but while engines out
its easyer and better to mount brackets to stop the manifold flexing down from the heat off of the engine and turbo
and the weight from the turbo

many thanks for the bolts mark

and erol come down when you can

thanks for the advices guys all helps

thanks hass
and zim_zimmer in used a second hand engine and built it up. the turbo shoild clear the bonnet

and

[RowdyBurns]

A couple of hints.

Make sure you washed that block out, oil galleries included, with plenty of degreaser and the high pressure water. The swarf from the honing will make a mess of you fresh engine if there is any remanents.

Dont put engine parts that have a bearing surface like cams on a concrete floor.

Same goes with pistons

Engines should be built spotlessly clean on a surface you could eat your dinner off.