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Morph

Rebuild Updates ....... please add yours

Rebuild Updates ....... please add yours  

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First off sorry I've no pics but me camera charger is fecked. I've gotten to the total stripdown stage so my engine is strewn across a friends shed in many many pieces. That was the good news, the bad news is that I threw a tip seal which welded itself in the rear housing so both the housing and the rotar are fubar. This is this 1st time I've stripped an engine and I was suprised at how easy it actually is. After taking the engine out I recon that I could have stripped the engine completly in a day if it wasn't for that darn pesky main engine bolt (took 3 days for that one bolt, note to self get a bigger torch). The main engine bolt needed some serious heat to get out. It'll be a while till I get the new rotor and housing from Japan but the saving is worth it. It also gives me time to shop around for other bits and pieces. I've decided to do as much as I can while the engine is out since at the moment I have another car and a place to work on it. New single turbo should be here at the end of the month along with the new clutch. The new rad is here already along with the rebuild kit and porting templates etc.. Need to order intercooler but it only takes a week so not in a hurry til I get paid again Currently looking at fuel rails any suggestions? Who here has upgraded their injectors?

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My update... My Update: Not gotten as far as you yet Morph, started at it last week. Got most things out and almost ready for taking the engine out. Possibly the end of the week or the weekend. Funds are low so not even ordered the rebuild kit yet. But like Morph i'm gonna take my time at it and try to replace everything that needs replacing while its out as I've got another car to keep me going. Prob going to remove the Air Con and Air Pump completely. Would like to get a bigger intercooler as its just got the stock one in at the moment and possibly a clutch if i can afford it too. Every time i start lookin at stuff on the net the list just keeps growing. Better off taking it slow and doing it right though, can't wait to get down to the bare block and see what damage is done too. Dimrod

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Ya getting rid of the airpump and aircon myself and have to replace the clutch as well so I'm upgrading that too. Thats the thing that ruined my budget and is keeping me waiting til the end of the month for payday. Forgot to ask in the first post but is the plastic vaccuum chamber actually neccessary 'cuase I busted it taking it out??

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update mines still in car just waiting for the word go from a friend and ill have it out in less than a day then its just a short drive ive been scowering the net for parts but i wont know what i really need till its stripped also im planning on a mild to maybe large street port(this depends on money really ie if i can afford the single turbo or not) anyways will let ye know how it goes as it happens seriously missing the car now i do have another car but its just the feel of sitting inside the fd low down,all the instruments pointing towards you the surge of power and the little flick of the ass coming off the roundabouts god i miss it big time :(

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howzit :) you can always get the stage 2 now and rebuild it and fit bolt ons later the ecu can cope with it you cant go that big on porting with fd's as they were designed very big to begin with, ive only got a little outta the ports compared to earlier engines. but polishing the inlet runners and ports makes a good difference later glen

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thanks glen more than likely it will be a small port ie because ill be using my single turbo money now to pay for the ultimate rebuild lol im planning on replacing as much as i can afford to ie seals,bearings,coolant pipes,boost pipes etc as i said tho this depends on the money situation after ordering the parts but i wont know how bad it is until i strip it down fingers crossed its not too bad

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Cheers Glen It's always handy to get input from the peeps in the know. Big shout out to Dimrod and Berniec :smt006 I'll be cheering you guys on since as far as I know we're the only ones rebuilding their own engines currently (well I suppose you.ve something on as well Glen, some monster fb or fc ). :lol: Three cheers for the amature builders support group :smt041

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thanks glen more than likely it will be a small port ie because ill be using my single turbo money now to pay for the ultimate rebuild lol
yes it will be a small port :) as i said you cant do a big port on the FD engines as they are at there limits anyways :):P safely you can only go 5-6mm higher on the inlet port :) later glen

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three chears ill be getting alot of help as in someone else will be doing most of the work but ill try and help out i dont know if he wants me to name him or not so im not going to just in case but if its ok with him and the jobs done ill be more than pleased to recommend him

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being honest glen i was thinking more along the lines of just a little scrape lol not 5-6mm but uve now made me think lol what ever size i choose it will be thought out for bout performance and reliability and drivability

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Woohoo shiney new housings and rotors arrived today and compression tube mmmmmmmm shiney :smt049 Just waiting on injectors now and will probably find out about misc bits and pieces I know I've forgotton :smt075

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Ok I attacked my housings and plates last night with a drill and a carbide bit (tried those dremel type grinding stones first not a scratch) which made short work out of the job. They seemed to come out fairly ok I used a set of templates I got from pineapple racing. Added about 2 - 3mm to the size of the intake ports and smoothed the channel a bit nothing too drastic. I decided to stop when I thought I had them both even. Took off about 2mm below the exhaust lip and smoothed off all round. Word to the wise wear gloves, carbide bits take the metal off in shavings and I may have trouble getting through metal detectors in the future with the amount lodged in my skin :twisted:

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Update: Finally got the engine out with the help of a few friends. Thought it would be tough enough to squeeze it out but it came out pretty easy. Took the transmission out with it. The bolts from the gearbox/diff brace were seriously tight and I needed to get a long reach 21mm socket for some of them too. Once we got the engine out we got stuck in to stripping it down to the block, taking pictures along the way to remember where everything goes, gonna be some jigsaw to put back together. The flywheel has alot of scorch marks on it and there is loads of small cracks all the way around it too. Pic below... The turbo also has a nasty crack... Pic below... Will try and sort all the parts today, still trying to source a 54mm socket to take off the flywheel nut, looks as though someone had it off before with a chisel instead of a socket. Moved the rotors around and had a look in through the ports and all the tips look pretty intact as far as i can make out. Out with the Donkey.... 2wly62t.jpg Down to the block.... 10zbfc2.jpg Cracks on the flywheel.... (cracks like this all the way round) 2crvaq0.jpg Crack on the Turbo unit.... 205cks9.jpg

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The crack on the turbos might be ok....somebody more experienced might be able to comment? TBH Id be more worried about the metal filings showing in the turbo housing picture - looks like the inner surface of a rotor housing to me Also is that a hole in the inner section of the flywheel? I can sort you out with a flywheel socket if you want? and as podge said: keep the pics coming!!

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The crack on the turbos might be ok....somebody more experienced might be able to comment? TBH Id be more worried about the metal filings showing in the turbo housing picture - looks like the inner surface of a rotor housing to me Also is that a hole in the inner section of the flywheel? I can sort you out with a flywheel socket if you want? and as podge said: keep the pics coming!!
Don't think they're metal filings in the turbo housing, just dirt from around it when taking it off i think. There's 4 factory holes on the flywheel, just the angle the photo was taken looks bad. Might take you up on the offer of the flywheel socket, my boss in work said he had one but if he doesn't arrive down with it i might just get a lend off you if you wouldn't mind. I'll keep the photos coming don't worry.

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Just noticed that on the end plate behind the flywheel where all the main bolts go, all the bolt heads have been numbered with black marker. Is this a sure sign that the engine has been rebuilt before do ye reckon?

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Just noticed that on the end plate behind the flywheel where all the main bolts go' date=' all the bolt heads have been numbered with black marker. Is this a sure sign that the engine has been rebuilt before do ye reckon?[/quote'] Yip, I would think so

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Good on ya dimrod! Sorry I haven't posted here in a while, been busy. Figured out what nearly killed my engine anyway, it was one of the oil metering lines. It had cracked with age and instead of lubing the engine it was lubing my driveway. We'll just have to put this one down to experience, my own fault for not investigating the oil leak fully I just assumed it was the sump gasket. Replaced the damaged housing and rotor and did a little porting on the air intake and the exhaust, not alot just a mild port. When the time came I ended up putting the short block together myself. Pretty straight froward after watching the DIY RE set of dvds. I didn't have an engine stand just did it on a bench. I found it was easier to do it on two planks of wood supporting the edges of the engine so I could tip it over without fouling the eccentric shaft. A couple of tips: cover the water jacket with tape to avoid loosing small pieces down there. I was installing the last seal when the end popped off and fell into the open holes. so I had to pull it apart and start again. If anyone has watched the extras on disk 4 of DIY RE this is exactly what happened to me :evil: Lets just say a few expletives were bouncing off the walls for a while. I also found that if you are on your own doing this it's easier to pass the eccentric shaft through the center plate first and put them on together instead of dropping the shaft in first and placing the plate over it while manuvering the shaft. If you do it in the horizontal position it's easy and tip it back up to vertical to put in the next set of tip seals. Still not all the way there yet, I've a few things I need to get done and figured out. Had to get a counterweight off an automatic to fit the new OS Giken clutch assembly still need the bolts, the instructions for the turbo are in Japanese and I can't seem to find them in English and the new fuel rail has no instructions at all so I've to figure out how to wire it up (surely can't be that hard :wink: ). I'm just gonna keep going until bits stop fitting :lol: Sorry no pics at the mo will post when I get a chance.

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Well i eventually got the engine split.... That flywheel nut was rightly tight, had to heat it with a blowtorch for about 15-20 minutes beforehand and use a big lever on the breaker bar, sittin on it like a see-saw until it finally broke. After that it was all straightforward, Front rotor which had the bad compression had 3 broken apex seals, chipped the tip of the rotor and put a nice deep long gouge into the rotor housing. Heres the pics: Preperation: http://i26.tinypic.com/2i707k9.jpg Flywheel off and main engine bolts out: http://i32.tinypic.com/j8mng0.jpg Rear side housing off: http://i31.tinypic.com/be80t4.jpg Rear side housing: http://i26.tinypic.com/2mwxojd.jpg Rear rotor inside rear housing: http://i32.tinypic.com/1f7892.jpg http://i26.tinypic.com/farkif.jpg Rear rotor and bits: http://i29.tinypic.com/25rko0p.jpg http://i27.tinypic.com/10n5a3c.jpg Block with rear rotor out: http://i28.tinypic.com/2wmfiub.jpg Centre Housing and eccentric shaft out: http://i26.tinypic.com/ekojy9.jpg http://i32.tinypic.com/15y9q9k.jpg Front rotor in front housing: http://i31.tinypic.com/33mq3hu.jpg Front rotor and bits: http://i32.tinypic.com/2wq8q69.jpg http://i25.tinypic.com/25q7ihf.jpg The lot: http://i31.tinypic.com/6fma95.jpg http://i32.tinypic.com/51spyq.jpg http://i29.tinypic.com/315ifpj.jpg Damage to front rotor housing: http://i29.tinypic.com/157bz86.jpg http://i25.tinypic.com/2n0iof4.jpg Damage to front rotor: http://i27.tinypic.com/35mkxsh.jpg

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ok guys update for mine fiachra has been very busy with the tools and ive been busy trying to get the parts and stuff anyways my update is the engines out and stripped thats the good news now for the bad news,im not to sure about what caused the engine to go bang there is a few possibilities anyways the current state of the engine means i need the following front end plate intermitant end plate eccentric shaft(yes i need one) front rotor turbos housings(which came yesterday) amoungst other pieces the good news about that is i might have sourced second hand twins,s/h front rear and intermitant end housings,s/h eccentric shaft and all the other pieces i have ordered the atkins kit which should be here next week and ill be ordering a new rotor tonight oh and because one rotor is chipped i now have a nice paper weight lol anyways ill keep ye informed as it goes along

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driving home from town one night lol as i said im not sure what caused it just yet there is a few ideas but im not going to mention anything afaik the housings could be re used but i want to put fresh ones in the side housings just have heat damage and need to be relapped but its probably cheaper and easier to get s/h ones from the states im not to sure about the e-shaft but i think ill pick one up from the states as im at it too a few ppl have been saying to me that the rx is a money pit,my answer to them is i love it and its worth the money :D

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