298 replies to this topic

[techieboy]

Techie : I know, revolting isn't it!! EGR plate and cheater already purchased for the new engine, hopefully it will look better after some scrubbing!!

And the all important 10p piece and Araldite to block up the hole in the inlet manifold. Better budget for that.

[XXX]

Well done (so far) Jon! I assumed that you had sold the ginger-trimmed beast. Keep up the good work - Spring is on it's way.....

[rob999]

Enjoyed the read and journey so far and like others said, lots of respect for diving in. Keep up the good work Jon

[smiley]

Nice project. Don't pile stuff on your rear lights. The lenses scratch easily.

[oakmere]

Looking good. But it looks to me like you have fitted rear shox on the front?

[Andrew aka Stuwy]

Great project

[oakmere]

Looking good. But it looks to me like you have fitted rear shox on the front?

Just looked again and the Spax are a different design from other makes so I think I am wrong with the above quote.

[Tommo]

Great job! I've had a box of replacement bits that are due to go on mine for about a year and just can't get motivated to do it. 10/10 for effort and execution!

[gingerjon]

A couple of busy week sout the way and it was back to a surprisingly warm and sunny workshop today!

New toys had arrived courtesy of Lee, a spitfire toe link kit and brace bar. Thats would be the first thing on the list :

After it had just got used to having its wheels on...up it went!



Wheel off to reveal the shine once again....i can see why JG doesn't drive his!



New Toe link in place on Drivers side :



Passenger side :



Back down with new links in place :



I have a brace bar as well to fit, but waiting for the exhaust to go back on eventually and then i'll fit around it after reading a few poeple had issues fitting with certain back boxes. Also, i don't have the stainless brackets for the subframe end....anyone got any spare or know where to get just the brackets?

[gingerjon]

Then it was back to the engine and all the bits attached. I wanted to get as much off as possible ready to take the engine out and leave the gearbox in place.

Finally got the ECU off....man, those shear bolts!!! Read a comment Joe had put on a thread whcih said "Just drill it, you can't damage anything...." So with that certainty in my mind....i drilled it....




It went well!!

Inlet manifold was next to come out :

[gingerjon]

Bit of a nightmare.....the end of the dipstick tube has snapped in the block.....this shows how much is still in there....any ideas?



Alternator next...the bolts are much longer than you think!! WD40 came to the rescue.




The belt had clearly seen better days :



Starter motor followed now there was enough room to get down the back of the block :




Which left everything disconnected from the engine except the gearbox and the mounts themselves :



A pile of bits removed today including the fuel rail :



All put away til next week......hopefully see the engine finally removed......

[hairy]

Re broken dipstick - some ideas here:

http://www.homenetwo...r-Nissan-Sentra

[gingerjon]

Well as i was going to in the workshop on my own today i decided to leave the engine and start with the bolts for the steering rack....

...After 30 mins of trying to line it up, hold it in place and get the bolt in and failing....i decided that job could wait!

Then with a "Whats the worst that could happen" thought, i decieded the engine was next on the list :



I had removed everything i thought i needed to over the last week and it was time to try and get the thing out!

I put the hoist in place to support the whole thing as i set about locating and loosening off the 7 gearbox bolts...wow, they are awkward to get to!!



Removing the Drivers sidee Engine mount bracket was reccomended on a few threads to give some vital extra room

[gingerjon]

Upon looking at the passenger side mount (attached to the gearbox) i discoverd a small clue as to what may have been causing the noise under acceleration last time i drove it....



Not sure if this is the cause, but i'm sure it contributed....

I removed the front and rear mount mounts (I now know thats not needed) But i had some powerflext inserts to put in also.



Then after a little prise with a precision tool (Crowbar) out it came and up it went!!!



And thats it....the scariest job i thought turned out to be one of the easiest so far





All done and looks a bit wierd!!



I'm working away now for a couple of weeks so the car will stay as is until i can pick up a few parts i need before the new engine goes in and a whole new game of "Where did that go?" begins!!

Jon

[gingerjon]

Well after what seemed an age, i returned to the car. Unfortunatley whilst i had been workign away, no one had finished it for me!

Straight to work as there was a lot to catch up on. New parts had arrived over the last few weeks ready to replace the old :
Fast Road Clutch
Slave Cylinder
Lightened Flywheel (Thanks to the Most Arctic of Monkeys!)
Interim Heater (Courtesy of Fab!)
Poly inserts fro front and rear engine mounts

Slave Cylinder was 1st on the list:
The old one i assume was the original and had seen better days


Undoing the 3 Torx Bolts and the feed for the fluid was easier than anticipated


New and old next to each other showing the the life had definately been sucked from the original!


New one in a connected :


I have re used the green "Boot" from the old one as the new didn't come with one, is that going to make a big difference?

[gingerjon]

The New engine for the car was from Cliffie, it's done half the miles of the old one and also had its chain changed recently. I picked up the lightened flywheel to go with the clutch i order a few weeks back and began the swap
Before :

Old and New, there is a large amount of material that is removed to make the lightened version, hopefully will make a difference

New Clutch

All fixed, lined up and tightened up


Now the engine is ready to go back in its that time where i begin to think i should have labelled more of the various plugs and pipes....a daunting task ahead i think. The engine will go back in once i have managed to put as many of the ancilleries back on out of the car as i can.

The front and rear engine mounts were alright but for the sake of £40 i thought the inserts would be a good bet :


With the mount out the inserts just plugged in

Rear mount back in :

Front inserts in just before it goes back in

[gingerjon]

The Passenger engine mount had broken and i had a new one left from when i changed it last time.....seems the OEM one on the drivers side has been fine yet the passeneger ones from Autovaux didn't hold up for quite as long. I'm hoping the poly inserts will help that now

Wheel off and the variety of sockets needed to get in through the small area was a Krypton factor moment in itself!!

No wonder there was a slight "Knocking"

Poly Mounts in and new top mount done

I started taking some of the extras off the old engine to transfer to the new one.....some may not make it.....


Any one know the part number and if they are easy to get hold of?

[The Batman]

well easy bud, just go to any motor factor shop z22se belt tensioner around £40 ask for discount

[gingerjon]

Couldn't resist trying the newly painted rocker cover on for size

There is a difference on my old engine and new engine around the Oil Filter housing.....does anyone know if i will need ot do anything and where the existing pipework will go in the car?
New

Old


A clean of the inlet manifold and back on it went


A couple of the studs that ar in the block of my old engine are not it the new one, can you get new ones to put in the block?


Last job of the day was to get the new heater in place ready to connect when needed. It's only going in to gte the car started as i'm hoping to either not use it at all, or get a Fez heater when the time comes.
I'd forgotten how small that hole was!!

All in place

And once again, the realisation that there are a LOT of wires that need re connecting to somewhere!

Thats it for today, going to get the Radiator, coolant, oil, spark plugs and hopefully a new exhaust manifold ordered next week, then the engine can go back in and if i can remember how to connect everything up, she may live again!

[The Batman]

put all of your original oil cooler stuff on as mike kept that for his car. any chance you can hunt down a 2.4 mani? ported throttle body? worth a go!