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Author Topic: Long overdue engine refresh  (Read 465 times)

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Offline terry47

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Long overdue engine refresh
« on: February 07, 2015, 04:53:33 pm »
Well I'm going to join the happy band of Customer Cars shortly. I delivered my neglected 2l 16v (apart from regular oil changes, every 100 miles, it hasn't been touched in 13 years) to Jason on Tuesday for him to work some magic with it.

In it's current configuration it has 204 bhp at the flywheel and 155 ftlb but a quick run on the dyno will see what it has now. Then it will be a strip down, measure and rework. I know what I'm looking for in terms of power and the master says that should be easily achievable, so watch this space.

I don't know if there will be any regular updates on progress depends if Jason has the spare time, whatever that is! :D
Mk2 Golf GTI (well that's what it started as!)
Audi A3 S-Line Final Edition Cabriolet

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Offline Jon Olds

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Re: Long overdue engine refresh
« Reply #1 on: February 07, 2015, 11:39:45 pm »
Hello! Good to see you are still racing the beast!
Jon

Offline Tristan

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Re: Long overdue engine refresh
« Reply #2 on: February 08, 2015, 02:40:36 am »
Decent figures! What's the spec?

Offline terry47

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Re: Long overdue engine refresh
« Reply #3 on: February 09, 2015, 09:38:32 am »
It's current spec is;

2 litre 16v, gas flowed head, solid lifters, REC valves, Arias forged pistons, Arrow steel rods, lightened and balanced crank, billet steel flywheel, Jenvey throttle bodies and TVM inlet manifolds, along with a baffled sump and Brise starter motor. Unsure as to cams can't remember if they are Piper or Kent. Powerspeed custom exhaust manifold and single box exhaust system. It has a full DTA engine management system with a current rev limit of 8100 rpm that produces 201.6 bhp (182 bhp at the wheels) and 155.1 lbft of torque at 5764 rpm. Davies Craig electric water pump, custom 3-core aluminium radiator and electric fan.

I doubt if it will that much different once Jason has finished his work, I know he's going to look at the head as well as doing things with the crank. As we don't know about the cams then these might change as well but I'm waiting to see what is said about them. Then when all the work is done we should have a good increase, not saying at the moment what that is hoped to be other than to say considerable.
Mk2 Golf GTI (well that's what it started as!)
Audi A3 S-Line Final Edition Cabriolet

Offline terry47

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Re: Long overdue engine refresh
« Reply #4 on: February 09, 2015, 09:42:35 am »
Hi Jon

Yes it's still going strong even despite the neglect it had.

I see yours is still about as well, even featured on Motors TV for the Jack Frost (I've only seen the first 5 minutes so you may appear again). Well you are in good company I was shown for the Brands Hatch Stages in January 2013 complete with body modifications that I inflicted at Graham Hill Bend on SS1. MAD videos has the incident on their teaser for the rally.
Mk2 Golf GTI (well that's what it started as!)
Audi A3 S-Line Final Edition Cabriolet

Offline GEL

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Re: Long overdue engine refresh
« Reply #5 on: February 09, 2015, 01:10:45 pm »
Hi Terry,

Good to have you `over` here !

With my valver also with Jason, after nine years unused and just eighty running in miles ... I don`t feel that bad now  ;)  ;D

Look forward to the results ...
Mk1 Golf GTI 16v
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Offline Jon Olds

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Re: Long overdue engine refresh
« Reply #6 on: February 09, 2015, 06:39:38 pm »
Ha, Isn't it always when you have a moment you get caught on film! I had the same car out 2 weeks earlier at croft (xmas stages) and had a steady run through all eight stages without so much as a broken wing mirror
oh well
new panels going on soon, damage is purely cosmetic
Interested to see the 'after' graphs, terry, your motor is in good hands.
Jon

Offline terry47

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Re: Long overdue engine refresh
« Reply #7 on: February 25, 2015, 07:52:34 am »
Well Jason has run up the old engine on the dyno and I'm pleasantly surprised at the results. Even after 13 years of neglect it still has 157 ftlb of torque but he cut the run as oil started to spray out from the breather on the block (as there was no pipe connected) but it still showed 194bhp.

So those figures are not too bad after all this time, but Jason did say the compression was a bit low, which makes the figures even better. Now it's just a case of waiting until all the measurements are taken and then work can start. Can't wait to see what the next run on the dyno will produce after all the work has been done.
Mk2 Golf GTI (well that's what it started as!)
Audi A3 S-Line Final Edition Cabriolet

Offline Jon Olds

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Re: Long overdue engine refresh
« Reply #8 on: February 25, 2015, 08:16:09 pm »
Not shabby at all
Jon

Offline GEL

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Re: Long overdue engine refresh
« Reply #9 on: February 28, 2015, 12:30:55 am »
Thank you Terry ... a good start  ;D
Mk1 Golf GTI 16v
Alpina B10 V8 Touring
Audi S4 Avant V6 quattro

Offline terry47

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Re: Long overdue engine refresh
« Reply #10 on: January 01, 2016, 03:57:24 pm »
Well I don't know about a long overdue rebuild, I think an update is also long overdue.

To say its all been plain sailing would be a bit of an understatement. After the dyno run back in February things went a little quiet and then Jason started to strip down what I thought had been a good little reliable engine. Well to cut a long story very short I was surprised that it could pull a skin off a rice pudding when all was said and done. Old technology pistons, cam timing a bit out, low compression and a head that was just above standard. Well I suppose if its not stressed too much it's why it lasted so long.

What could be saved? Well the rods were okay and so was the head when it had had a lot more work done to it. So what was initially going to be a quick 1,500 rebuild was now escalating to the heights of a new engine.

A new block was needed as this had been bored to 83.5mm along with the spare and Jason wanted 83mm. So the hunt was on. Found one in Birmingham which was allegedly from a 157000 mile Corrado in good condition.  Well it arrived and not really as described, it took a month of sundays to clean the oil from it, but at least we now had a block and crank. So he set to work cleaning and getting things started.

Then he started on the head, I'm just glad i was not in earshot when this happened. Everything he touched was not to his liking, and Jason is not for just making do he wanted this to be right. So 'a lot' more work was needed on the head to get to his standard which as we all know takes time.

So with most of the work done on the block and head he thought it would all go together without any further problems. Well think again. New bearings ordered and received, and theses were twisted. Replacements ordered and received, and these were oversize. Lets hope the third set is okay, success at last so the block can now be assembled.

Here is a picture of the block now all nice and clean and painted, certainly be able to find it in the dark.


Here is a picture of the nice balanced and knife edged crank.


Picture of my nice new pistons in situ.


And finally part of the head after the extra work has been done.

Well thats all for now, as things are going Jason expects it to be ready for collection by the middle of the month. Just what I need in these cold and dark days to be fitting the engine and box outdoors. It is not something I relish at my age, I thought I'd done with all that but beggars can't be choosers so I just grin and bear it. Just think of that smile on my face when I start it for the first time, I'll be like a kid with a new toy.

Still not going to say what power its going to have, not until its been dyno'd but the smile may just get bigger.
« Last Edit: January 02, 2016, 08:51:32 am by terry47 »
Mk2 Golf GTI (well that's what it started as!)
Audi A3 S-Line Final Edition Cabriolet

Offline JMR

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Re: Long overdue engine refresh
« Reply #11 on: January 04, 2016, 09:16:56 am »
 ;)

 

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