My "new" sickness .. aka Max. (1 Viewer)

[tmarx]

Update pics.

We found oil on top of piston 6 and 3 which we suspect is oil that leaked down the valve guides but can only confirm once the head is at the Eng shop.

We were right in our earlier assessment that this was in fact a complete new sub-assembly. Only 2 of the cyl walls had slight scouring marks and the oil rings had slight play - probably from the seller doing that 1st start up on old oil after standing for more than 2 years without cold cranking and building some decent pressure. On all cyl walls the factory hone marks are still clearly visible so this assembly has not worked hard or long.The bearings and crank are all good.

This is the worst one ..

 

[tmarx]

While waiting for the block and head from the Eng shop the new 300mm 21spline clutch arrived.

 

[tmarx]

Well now we know why it was smoking - report back from the eng-shop is that the valve guides of those two wet pistons were completely shot ..... so the head will be completely rebuilt.

 

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While we are waiting for Toyota to supply us with a 1HD-T pressure plate in order to finish the last of the balancing work by the Eng shop, we had some time to confirm the accuracy of their other balancing work

 

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Finally it arrived !!

 

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Rather unexpectedly I stumbled onto a sweet deal for this ARB bar off of a 2003 narrow nose 79, which should fit my 75.Hope to have it here in about 2 weeks

 

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Ok with all the new and balanced parts ready we got going ...

My mate the master of all things cruiser, himself

 

[tmarx]

 

[scrapdaddy]

I'm not sure what it is, but I really like looking at engine guts. Doing it right!

 

[tmarx]

The latest progress ...

I can honestly say that I am as excited about this process if not more, than what I was just before starting Olive for the first time after 2 years !

 

[tmarx]

Hot off the "press" for today ...

 

[tmarx]

A small update ....

On another note, my ARB arrived and I was pleasantly surprised with the general condition.

I will need to replace the flicker units but I understand that those from a Golf MK1 are a perfect match ? I did manage to locate one of these with the help of R&D Off Road

and then I thought with the engine getting a new lease on life, it deserves a new ...

 

[tmarx]

Moving along ..

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The block to compensate for the ACSD disconnection ...

 

[tmarx]

Measuring the piston protrusions

The newly rebuilt IP

Now waiting for a MK5 HG from Toyota.

 

[tmarx]

Stock boost for a 1HDT CT26 turbo is 11 to 13 Psi. The turbo on my engine was a newly rebuilt (to OEM spec)unit, which we fitted 5 months ago. After fitting my MGL Avionics boost gauge the highest I ever recorded was 0.78 bar or 11.3 Psi. This was not to my liking and after considering fitting a manual boost controller, I settled for the option of just spacing the waste gate diaphragm - I only wanted to gain about 2Psi so 2mm was what I wanted

I am sooo jealous of his array of tools ...

Before ..

and after

from 11.3 Psi to 13.1Psi is just what the doctor ordered - after I/C I can add some more

The turbo unit itself developed a small coolant leak from the first week and we thought it was just the gasket ....

but instead of mucking about we have agreed to just replace the entire pipe with a new unit - it is just too much labour to take chance on a potentially hairline cracked pipe ...

 

[tmarx]

The latest progress while we are still waiting for our MK5 Head Gasket ...

the end is nigh

 

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[tmarx]

And eventually it was time to collect her and since then I have not been able to stop smiling - the car pulls even better than before. Superb job JB and crew !

 

[61Mk+]

TMarx, this is beautiful, and i am experiencing pangs of jealousy.
Question: after such a rebuild, i'm curious to know details of the break-in period please.

 

[tmarx]

Thank you kindly, sir.

As for the "break-in" period length I will endevour to resist the temptation of being a boy ricer for the first 2500 km but thereafter I cannot promiss anything.I collected her with 12 km on the new motor and it was right in the middle of us moving house so I drove straight to the local trailer rental outlet and put some controlled medium load on the motor with the odd boost inbetween.I am convinced the rings have "bed"already and today after 200kms the oil was still on the same mark and super clean, albeit to the eye only.The rep said to only change that oil after 5000 kms but I am still pondering a change at 500 kms