Supercharged - Take Two

Catlin

Member
Really should have started this thread a lot sooner but here's a quick look at the process of rebuilding my engine since it went pop at the end of last year. I'll try to keep this a lot more up to date from here on in.

Couple of pics of me sat at the side of the A5 after a big bang and all of my oil deciding it would rather be on the road than in the engine. RAC bloke helpfully suggested pouring a litre of oil in (all he had) and giving starting it a go. I politely declined and had it towed!

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It transpired that one of my rods had shot through the back of the block (pic of the damage later) so a replacement bottom end was order of the day. I quickly decided I wanted to do a proper rebuild, ditching the old six injector setup and going with the newer setup that everyone else seems to be running. If the car was going to be off the road for a while I might as well do everything properly.

So introducing, the brand new bottom end:

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Complete with date of manufacture sticker, it didn't appear to have been out of the box since.

The focus then moved on to removing the head from the old engine to check for damage. Carl who has been helping out (saving me) throughout agreed on a deal to swap my head and some cash for one he'd ported and polished (pics later), so I got on to stripping more bits off (when I say I, most of this work was actually completed by my mate Paul).

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Eagle Rods and Wiseco Pistons were ordered to try and avoid throwing a rod again and get the engine ready for a hopeful power increase.

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Popped to Carl's one Sunday to collect the head and ended up staying all day as he gave me plenty of advice, didn't expect to be leaving like this:

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Was well worth it when I got this home, Carl did a great job, even fitting his own hydraulic lifters to it when there was a doubt around those already fitted. Valves were also swapped out for Saab sodium filled ones.

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Never thought in my life I'd own an engine stand (or the engine crane that has followed) but her it is as things got moving.

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Balance shafts out and cut, bearings knocked in.

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Rods assembled, rings gapped and pistons in, then timed up.

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Inlet manifold ready to go off to be tig welded.

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Block lacquered:

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Then finally time to take the old engine out to allow me to start tidying up the bay ready for the new engine.



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Getting a few bits tidied up for the new engine.

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And finally where I am now:

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Hoping to get it in over the next couple of weeks, really need to get the bay freshened up a bit and get the loom sorted. Few changes required moving from six injectors back to four, injector plugs for the Z20LET injectors should be with me tomorrow as well as some loom tape to tidy things up and replace the plastic sleeving Courtenay had used originally.

Need to buy a new coolant tank and have been toying with the idea of silicone hoses but have read mixed feedback on them
 

Dave Gilbert

Senior Member
Will you be ready for pvs?

And would you like to join us?

We will have a great stand with more chargers n turbos than standard.

Looks great work.

n you did a propper job of destroying your first engine
 

Catlin

Member
I'm hoping it'll be ready for the PVS date as I've booked a ticked for Opel Treffen Oschersleben in Germany which clashes this year which is a shame. Last couple of years I've managed to fit in Opel Treffen one weekend and PVS on the TV stand the next.

Does Z22SE attend Billing?
 

Sjdickso

Staff
Nice build thread good to see you putting it back on the road, do you mind me asking what power it was putting out?
 

milo

Senior Member
Nice job on rebuild(y) Is the new bottom off ebay? As im going the same route and seen new bottom end selling for 500. Also could u be kind enough to tell me where u got the piston and rods.
 

Catlin

Member
Nice build thread good to see you putting it back on the road, do you mind me asking what power it was putting out?

It made 233bhp when it had just been put in first time round, although it never ran perfectly. The engine ran 250bhp whilst it was in the SRI I bought it in. Hoping for a bit more once it's in again.

Nice job on rebuild(y) Is the new bottom off ebay? As im going the same route and seen new bottom end selling for 500. Also could u be kind enough to tell me where u got the piston and rods.

Yeah it is one of the two new bottom ends the guys on eBay were selling (I believe the second one has just sold for a lot less:(). I got the pistons and rods from Titan Motorsport, again on eBay. Had to take out a brand new set of rods and pistons to fit them, which reminds me I need to get them up for sale on eBay/here.

Went to my local dealers this afternoon to pick up ten manifold studs and nuts that I'd ordered on Saturday morning, walked up there to find that the bags that were both marked as containing ten items contained eight nuts and seven studs! Wasted journey, fingers crossed they'll have them all in by Saturday.
 

5M1THY

Senior Member
He's a good lad.. when I was saying about charging my van he told me about yours.. I'm liking the look of your engine now did you paint the rocker yourself? My engine cover was red but I can't use it now so need to brighten it up abit lol
 

Catlin

Member
Well the engine is now running although all is not well. Idle is really lumpy and when revved often the revs won't drop back down past about 2k. The EML came on too and with my OpCom dieing I went to ECP to buy a code reader, It's been reading P1514 throughout the day aswell as P0340 later this afternoon. I looked up the P1514 code on this forum and worked through some of the suggestions around the ECU being earthed (which we'd missed) but to no affect. When running the car feels like it's running very rich.

This morning the temperature gauge wasn't working at all but after removing the temp sensor and replacing it it is now reading, First thing this morning the car ran OK and sounded a lot better but seems to have got worse throughout the day.

The oil pressure light has also been fading in and out this afternoon after us having no issues with it this morning. We took a look under the oil cap and oil appears to be getting around no problem, there's not rattling/metallic noises either. The engine has a metal cap on the oil filter housing from a VX220 I believe, when the sensor is unplugged from the spacer on this the oil light goes off completely. I'm not receiving any fault codes around this.

Any help or suggestions are much appreciated.
 

milo

Senior Member
Dave Gilbert u asked on post 2 of the thread and he replied Post number 3 of the thread lol
I'm hoping it'll be ready for the PVS date as I've booked a ticked for Opel Treffen Oschersleben in Germany which clashes this year which is a shame. Last couple of years I've managed to fit in Opel Treffen one weekend and PVS on the TV stand the next.

Does Z22SE attend Billing?
 
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