2011 Engine Rebuild

January to April 2011 - Engine Rebuild

The early months of 2011 were spent sourcing replacement components at reasonable prices for the engine rebuild. The cylinder head arrived back from the engineers and is now all ready to run on lead free petrol. The crankshaft was reground .010 and new main and big bearings obtained. The pistons and bores were found to be within tolerance, so a thorough cleaning and new piston rings were the order of the day. Similarly the camshaft and its bearings were within tolerance, a new clutch assembly and cover were sourced along with many other necessary spares such as timing chain, gasket set etc.

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The cylinder head upon return from engineers shop.
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The cylinder head upon return from engineers shop.
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The reground crankshaft upon return from engineers shop.
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Main bearing end caps and thrust washers.
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The pistons after checking, cleaning and fitting of new rings.
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The camshaft and bearings.
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Engine block given final wipe down.
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Engineers 'blue' removed from crankshaft and oil galleries thoroughly cleaned out.
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Camshaft refitted and in go the main bearing shells.
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Middle main bearing end cap and thrust washers fitted.
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Main bearing end caps all fitted. Nrs. 1 and 2 pistons also in situ and big ends bolted up.
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All four pistons in situ with big ends bolted up.
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After final check with torque wrench the locking tabs are bent over.
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Rear engine plate fitted - note new spigot bearing fitted in end of crankshaft.
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Front engine plate is next to be fitted.
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Refurbished sump oil strainer is refitted plus new cork insert seals to front and rear of block.
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The flywheel is fitted using new nuts and locking tabs.
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The new clutch assembly after fitting.
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The sump pan is refitted using new bolts and washers.
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The engine stands upright once again!
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The engine stands upright once again!
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The crank and camshaft gears are refitted along with new timing chain and refurbished tensioner.
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Oil thrower is refitted to front of crank timing gear.
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Timing cover fitted using new bolts and washers. Crankshaft fan pulley is cracked and will be replaced.
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Front engine mounting brackets are fitted.
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Close up of clutch - rear of front mount bracket visible at top left.
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Cylinder head studs are refitted. Alternator mounting brackets fitted - visible on RH side of engine.
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The cylinder head upon return from engineers shop.

The reground crankshaft upon return from engineers shop.

Main bearing end caps and thrust washers.

The pistons after checking, cleaning and fitting of new rings.

The camshaft and bearings.

Engine block given final wipe down.

Engineers 'blue' removed from crankshaft and oil galleries thoroughly cleaned out.

Camshaft refitted and in go the main bearing shells.

Middle main bearing end cap and thrust washers fitted.

Main bearing end caps all fitted. Nrs. 1 and 2 pistons also in situ and big ends bolted up.

All four pistons in situ with big ends bolted up.

After final check with torque wrench the locking tabs are bent over.

Rear engine plate fitted - note new spigot bearing fitted in end of crankshaft.

Front engine plate is next to be fitted.

Refurbished sump oil strainer is refitted plus new cork insert seals to front and rear of block.

The flywheel is fitted using new nuts and locking tabs.

The new clutch assembly after fitting.

The sump pan is refitted using new bolts and washers.

The engine stands upright once again!

The crank and camshaft gears are refitted along with new timing chain and refurbished tensioner.

Oil thrower is refitted to front of crank timing gear.

Timing cover fitted using new bolts and washers. Crankshaft fan pulley is cracked and will be replaced.

Front engine mounting brackets are fitted.

Close up of clutch - rear of front mount bracket visible at top left.

Cylinder head studs are refitted. Alternator mounting brackets fitted - visible on RH side of engine.