Ian's S4s refurb

[Dan E]

@Chillidoggy where did you get the labelling done for the air compressor switch, thinking that might work in our new kitchen, thanks 

[Sparky]

Have you checked the compression ratio?

[CHANGES]

24 minutes ago, Sparky said:

Have you checked the compression ratio?

 

[Chillidoggy]

If you piss staking bastards had spent more time looking at the engine instead of shonky writing on a wall plug, you could have saved me half an hour by spotting my schoolboy error of the air-con tensioner being upside down. 

[Chillidoggy]

Hoisted the engine up, flywheel and clutch bolted on. The usual problems with lining up, but I finally got the gearbox mated to the engine, and lowered into position. The wife directed the pre and post-install garage clean up, supervised the engine lifting arrangements, and handed me the correct tools when required. By way of a thank you, I’ve put a bottle of cheap Asda Prosecco in the fridge. I know how to treat a girl.

 

[Dan E]

That properly made me laugh 😂

[Dan E]

Looks like a bit of @Barrykearley mini trunking though will lend him a square at some point and explain the complexities 

[Chillidoggy]

Started putting back the snake’s wedding that is an S4s engine loom. I can’t help but think there’s a simpler solution, not that I’m about to rip it all out and start again. Trying to run the wiring where it wants to go with the least strain, I made some good progress, and there’s light at the end of the tunnel.

I thought I’d better see whether it could make oil pressure before I got too much further, so out came the spark plugs, fuel relay, and crank sensor. Thought I’d cheat and use jump leads on the battery, but I couldn’t get a decent enough connection to turn the starter, so the battery went in the car. Spinning it up, no untoward noises or knocking, so that was a bonus. I gave it about 10 seconds to be kind to the starter, then checked the oil level, which had gone down, so good news. Another 10 seconds, and the pressure gauge was just over the red. The sump level had dropped again about a litre or so, so I figure I now have oil pressure and can continue onwards.

I’ve ditched the FPR nylon return line in favour of some rubber fuel hose, and I’m waiting for some clips to arrive so that’ll be next week. Also, I’m waiting for a new inlet manifold vacuum connection to arrive. I’ve got two of them, but can I find them? Can I hell, I’ve searched everywhere, even emptied the bin, but no sign of them. No doubt I’ll find them as soon as the new one arrives.

[tomcattom]

Looks very neat and tidy Ian. The crinkle finish on the cam covers and chargecooler has come up a treat but the looks of it. If I can get mine even half way to that standard I'll be happy.

I've got to do something about the rats nest the previous owner called the wiring loom at the back of the engine on mine at some point - not looking forward to trying to sort that lot. Will probably wait and deal with that when I do the belts on mine for the first time this coming winter.

[Chillidoggy]

Tom - The wrinkle finish goes on well as long as you’re spraying it in a hot oven. If not, a hot-air gun is your best friend, you have to make sure the component is hot when the paint goes on, spray it, then play the hot air gun over it.

The wiring loom is what it is. Short of constructing a new loom, my suggestion would be to lay it in, see where the wiring ‘wants’ to go, then connect it. Hoses also have an impact on where it goes. Make sure nothing chafes, or hangs unsupported. You might have to do that a few times before you’re happy with the cable run.

 

Progress - I got the engine started after finding out the inertia switch was the reason the fuel pump wasn’t filling the fuel lines. Then the usual fill-up with coolant, and the long-winded ballache known as ‘bleeding the f*&#ing air out of the charge-cooler system’, which usually turns out to be a 3-day job on my car. Shame Pro-Alloy didn’t put a bleed nipple on top of the CC rad, but there you go.

The engine runs fine, no banging, clanking or knocking, so I must have done something right. It’s reasonably quiet, or as quiet as a 910 could ever be, and definitely quieter than before. Oil pressure was 4 bar on start, which settled back to 1 bar at idle, but the oil wasn’t  up to temperature so I’ll check that later. I haven’t balanced the throttles either, I need to get a meter for that, and the TPS will need setting, too. No CEL light illuminated, and everything seems to function as it should electrically.

Thus far there’s no oil leaks from the engine or gearbox, whoopee! I might even push the boat out and put the undertray/oil catchment device back on at some point. The exhaust emission is clean, the previous incarnation would cough black soot out on start-up like some old smoker in the morning before lighting up his first fag, however this new version is clean as a whistle.

I’ve still got work to do, the tailgate has to go back on before I put the boot floor in, then vacuum pump and connections, and do an idiot-check of absolutely everything I’ve done, making sure all pipework and electrics are properly secured, and protected against chafing.

It’s taken a long time to do, but I haven’t been in any hurry, and I was held up some by parts supply and waiting for cylinder head work to be done. Time will tell, but hopefully this will have been a good job. There can’t be much else left to do on the car now, probably easier to list what hasn’t been done, but I’m sure I’ll find something else to tinker with.

 

[Sparky]

When you fitting the surfboard?

[Chillidoggy]

It would never fit due to the rear wing inversion.

[Sparky]

Esprit's up, dude.

[Chillidoggy]

With the rebuilt engine and gearbox now back in, and only the tidying up jobs left to do, I won’t be posting on this thread again unless there’s something interesting that develops, and even then I’ll probably post elsewhere on TLF. Hopefully, it’s been useful to TLF members, that was my sole intention anyway. It certainly wasn’t a vanity project, as I wanted to share the pitfalls, successes, the processes, and how I coped with what turned out to be a totally unexpected bloody marathon, when I’d only expected a sprint. All the work I’ve done has been in an attempt to improve and maintain reliability. And reliability is the key word.

Roll the credits -

A well-deserved special mention and thanks goes to Dave Lisle @CHANGES, for his sage advice and the loan of his engine building tools. Also, Connaught Competiton Engines for their precision work and knowledge of machining processes, and Paul Matthews of Forge Engineering for the UN1 gearbox rebuild and Quaife ATB install. Pretty sure I’d have been a lot worse off without them.

[Dan E]

Looks amazing Ian. Good job Sir👍

[Giniw]

Yep, very nice job indeed!

Edited June 17, 2020 by Giniw

[Steve V8]

Perfection as usual Ian 👍

[Giniw]

30 minutes ago, Steve V8 said:

Perfection

Well ... almost, actually: I just noticed the charge cooler plug is painted red, and I think it should not? Fortunately it's not too hard to fix ^^

[tomcattom]

Mine is painted red. I'm not sure how much mine can be trusted in the originality stakes though, given its chequered history

[Chillidoggy]

The red charge-cooler plug is a larger, aftermarket, performance modification which gives a 2 degree drop in charge air temperatures.

[red vtec]

Was the Spirt level on the wall setup to aid with getting the engine level?

[Chillidoggy]

2 hours ago, red vtec said:

Was the Spirt level on the wall setup to aid with getting the engine level?

If you don’t get it level, your skis will fall off.

[Chillidoggy]

First run out yesterday, a total of 39 miles.

Indicated oil pressure 3 bar @ 2,750 rpm hot. Coolant temperature steady @ 82C, no oil or coolant leaks, and I haven’t heard anything fall off yet. Engine is noticeably smoother than before, I suspect that’s partially down to the dynamic balancing, and it’s also quieter, with less rattling going on than it’s previous incarnation. Gearbox shifts perfectly, although I’ve not tried the ATB function yet, that will come later when there’s a few more miles on it. The CC circuit is still not fully air-free, nothing new there then, but it’s getting there.

[Sparky]

Don't bother talking to me unless you've done at least another 61 miles.

Edited June 20, 2020 by Sparky

[Chillidoggy]

4 hours ago, Sparky said:

Don't bother talking to me unless you've done at least another 61 miles.

 

 

Oh, and I forgot to mention that the cams are now timed 104/104, so that may also have made a difference to engine running.