Who's been a busy boy then? My GT4!

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mark3
Member

187

23-07-2018, 01:47 AM

Woohoo, its not back here from its 10 month storage for one whole day & work has started, engine and box are out! Took about 5 hours inc getting it clear of the car.

[Image: 2011-08-30140504.jpg]

tomorrow il be splitting the engine and box and fitting a very sexy OSgiken twin plate clutch i got last year, then prepping head and block surface for a 1.4mm Cometic mls head gasket thats going on with ARP studs & nuts

busy busy busy, lol

day two

We got the engine and box seperated today ready to install the OSgiken TS2B twin plate racing clutch, trouble is friction plate No 2 was really too worn to be reliable so a new plate has been ordered and @ £250 it means the cost of the clutch is £500 BUT it would be £1200 if new, the new plate will be here on Friday. im going to change the rear main seal too just in case

[Image: 2011-08-31153413.jpg]

Just as well the new clutch includes a new flywheel as the old one was in a right state

[Image: 2011-08-31153500.jpg]

OH and with the engine out i found the cause of my high idle problem that i coudnt iron out, some idiot at some time has bypassed the power steering idle up valve on the pas pump, the 2 vac hoses to the valve have been joined together so now it has a constant vac leak as opposed to only when you hit full lock.

Day three

I got the head off this morning and i was pleased to see NO CORROSION in the head coolant channels at all but good grief there all so blocked up I'm amazed it only overheated on boost lol

[Image: 2011-09-01084115.jpg]

Then i took some measurement off the OS clutch plates just to see how worn No2 plate was

[Image: 2011-09-01121750.jpg]

Compared to No1 plate which is in very good condition

[Image: 2011-09-01121916.jpg]

This leaves me with just under 1.4mm of compression of the plate/s assembly so with the new plate in all should be fine and dandy.

[Image: 2011-09-01124026.jpg]

New plate should be here tomorrow and the Extremely pleasant people at RB racing from where its coming from are even sending me an old input shaft i can use as a clutch aligner. i tend to wrap tape round an extension and this has always worked very well as you Can get it the exact size BUT with twin plates are twin splines, and not only do the plates have to be centred the splines have to line up too.

Also have a new rear main crank shaft oil seal coming too.

It looks like the gearbox has been overhauled some time in its life as there is orange sealer visible at the many casing joints AND the oil was like new, very clean and golden in colour too, so thats a good thing lol

Oh and i been thinking, the fact the PAS idle up valve was bypassed would have given me a loss in boost as well as a vac leak!!

mark3

23-07-2018, 01:47 AM #1

Woohoo, its not back here from its 10 month storage for one whole day & work has started, engine and box are out! Took about 5 hours inc getting it clear of the car.

[Image: 2011-08-30140504.jpg]

[Image: 2011-08-30141722.jpg]

[Image: 2011-08-30150655.jpg]

[Image: 2011-08-30153446.jpg]

tomorrow il be splitting the engine and box and fitting a very sexy OSgiken twin plate clutch i got last year, then prepping head and block surface for a 1.4mm Cometic mls head gasket thats going on with ARP studs & nuts

busy busy busy, lol

day two

We got the engine and box seperated today ready to install the OSgiken TS2B twin plate racing clutch, trouble is friction plate No 2 was really too worn to be reliable so a new plate has been ordered and @ £250 it means the cost of the clutch is £500 BUT it would be £1200 if new, the new plate will be here on Friday. im going to change the rear main seal too just in case

[Image: 2011-08-31153413.jpg]

[Image: 2011-08-31153446.jpg]

Just as well the new clutch includes a new flywheel as the old one was in a right state

[Image: 2011-08-31153500.jpg]

[Image: 2011-08-31160223.jpg]

OH and with the engine out i found the cause of my high idle problem that i coudnt iron out, some idiot at some time has bypassed the power steering idle up valve on the pas pump, the 2 vac hoses to the valve have been joined together so now it has a constant vac leak as opposed to only when you hit full lock.

Day three

I got the head off this morning and i was pleased to see NO CORROSION in the head coolant channels at all but good grief there all so blocked up I'm amazed it only overheated on boost lol

[Image: 2011-09-01084115.jpg]

[Image: 2011-09-01092139.jpg]

[Image: 2011-09-01092308.jpg]

[Image: 2011-09-01104017.jpg]

Then i took some measurement off the OS clutch plates just to see how worn No2 plate was

[Image: 2011-09-01121750.jpg]

Compared to No1 plate which is in very good condition

[Image: 2011-09-01121916.jpg]

This leaves me with just under 1.4mm of compression of the plate/s assembly so with the new plate in all should be fine and dandy.

[Image: 2011-09-01124026.jpg]

New plate should be here tomorrow and the Extremely pleasant people at RB racing from where its coming from are even sending me an old input shaft i can use as a clutch aligner. i tend to wrap tape round an extension and this has always worked very well as you Can get it the exact size BUT with twin plates are twin splines, and not only do the plates have to be centred the splines have to line up too.

Also have a new rear main crank shaft oil seal coming too.

It looks like the gearbox has been overhauled some time in its life as there is orange sealer visible at the many casing joints AND the oil was like new, very clean and golden in colour too, so thats a good thing lol

Oh and i been thinking, the fact the PAS idle up valve was bypassed would have given me a loss in boost as well as a vac leak!!

mark3
Member

187

23-07-2018, 01:48 AM

Day four,

New clutch plate arrives early, woohoo!

[Image: 2011-09-02130102.jpg]

and at 4mm thick it proves my No1 plate at 3.6mm thick has plenty of life left on it, woohoo again.

New rear main oil seal

[Image: 2011-09-02134550.jpg]

OS giken flywheel on torqued to 85lbft

[Image: 2011-09-02135440.jpg]

Plate 1 in

[Image: 2011-09-02135508.jpg]

Centre plate in

[Image: 2011-09-02135519.jpg]

Plate 2 in

[Image: 2011-09-02135542.jpg]

Pressure plate in

[Image: 2011-09-02140001.jpg]

clutch cover on and bolted up through 4mm of spring compression

[Image: 2011-09-02141600.jpg]

And a huge thank you to the guys at RB motor sport who was kind enough to lend me there clutch aligner/input shaft.

[Image: 2011-09-02141628.jpg]

Gear box and engine back together.

[Image: 2011-09-02151731.jpg]

Then work on the block started and went on, and on, and on.... Big thank you to TRD who has the patience of many saints when it comes to doing this, thanks again buddy.

[Image: 2011-09-02151749.jpg]

5 hours later it looked like this! its as smooth as a smooth thing thats been smoothed over, finishing off with 1200 grit wet n dry for an hour using WD40 as a lubricant for a finer finish.

The black areas between coolant channels are not a worry as the head has large channels there and exert no pressure on the gasket at all in those areas.

[Image: 2011-09-02175144.jpg]

Then the head

[Image: 2011-09-02185830.jpg]

Got it stripped of cams and what not to lower all the valves

[Image: 2011-09-02185836.jpg]

And this is what we had to start with

[Image: 2011-09-02190134.jpg]

Finished it off in the dark so more pics tomorrow when i build it back up and then fit it to the block.

mark3

23-07-2018, 01:48 AM #2

Day four,

New clutch plate arrives early, woohoo!

[Image: 2011-09-02130102.jpg]

and at 4mm thick it proves my No1 plate at 3.6mm thick has plenty of life left on it, woohoo again.

New rear main oil seal

[Image: 2011-09-02134550.jpg]

OS giken flywheel on torqued to 85lbft

[Image: 2011-09-02135440.jpg]

Plate 1 in

[Image: 2011-09-02135508.jpg]

Centre plate in

[Image: 2011-09-02135519.jpg]

Plate 2 in

[Image: 2011-09-02135542.jpg]

Pressure plate in

[Image: 2011-09-02140001.jpg]

clutch cover on and bolted up through 4mm of spring compression

[Image: 2011-09-02141600.jpg]

And a huge thank you to the guys at RB motor sport who was kind enough to lend me there clutch aligner/input shaft.

[Image: 2011-09-02141628.jpg]

Gear box and engine back together.

[Image: 2011-09-02151731.jpg]

Then work on the block started and went on, and on, and on.... Big thank you to TRD who has the patience of many saints when it comes to doing this, thanks again buddy.

[Image: 2011-09-02151749.jpg]

5 hours later it looked like this! its as smooth as a smooth thing thats been smoothed over, finishing off with 1200 grit wet n dry for an hour using WD40 as a lubricant for a finer finish.

The black areas between coolant channels are not a worry as the head has large channels there and exert no pressure on the gasket at all in those areas.

[Image: 2011-09-02175144.jpg]

Then the head

[Image: 2011-09-02185830.jpg]

Got it stripped of cams and what not to lower all the valves

[Image: 2011-09-02185836.jpg]

And this is what we had to start with

[Image: 2011-09-02190134.jpg]

Finished it off in the dark so more pics tomorrow when i build it back up and then fit it to the block.

Stoney
Posting Freak

2,117

23-07-2018, 02:05 AM

Good work.

ad: It was a tough call to make, but the Supercharged IS200 is being retired. Confused

ad:

Stoney

23-07-2018, 02:05 AM #3

Good work.

ad: It was a tough call to make, but the Supercharged IS200 is being retired. Confused

ad:

Lexusboy
Posting Freak

9,267

23-07-2018, 02:13 AM

Good work keep the thread running:thumbup1:

Lexusboy

23-07-2018, 02:13 AM #4

Good work keep the thread running:thumbup1:

mplavery
Posting Freak

906

23-07-2018, 03:46 AM

Great work mate! As above...love these write ups.. Makes me want to rip my engine out lol

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mplavery

23-07-2018, 03:46 AM #5

Great work mate! As above...love these write ups.. Makes me want to rip my engine out lol

[SIGPIC][/SIGPIC]
[COLOR="Orange"]JAPANESE PERFORMANCE FEATURE SEPT 2011 Big Grin

Phil01
Posting Freak

2,004

23-07-2018, 04:05 AM

ST185,,Good work mate, nice to see another GT4, keep us updated

Edited 03-09-2011, 01:39 PM by Phil01.

Phil01

23-07-2018, 04:05 AM #6

ST185,,Good work mate, nice to see another GT4, keep us updated

speedfreek
Posting Freak

1,338

23-07-2018, 06:44 AM

Loving this so far! Keep it up! Big Grin

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speedfreek

23-07-2018, 06:44 AM #7

Loving this so far! Keep it up! Big Grin

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[SIZE=3]'93 Mazda Eunos Roadster Turbo[/SIZE]
(Current project)

:thumbup1:Follow us on Twitter and join us on Facebook:thumbup1:

mark3
Member

187

23-07-2018, 10:55 AM

Gord Nice one, love seeing people do all the work them selfs :kiltsmilie:

Keep the pics coming

Haha maybe i should add that i do it for a living, i am http://www.mobilemechanic.org

Anyway, onwards ever onwards lol

Day 5!

Fit head and get engine and box ready to install.

This is where we got to last night with the head

[Image: 2011-09-03125854.jpg]

Block ready to accept the head with Cometic 1.4mm mls gasket in place

[Image: 2011-09-03125833.jpg]

Head on, torqued down to 90lbft in 10lbft stages from 30lbft using ARP stud/nut and the supplied molly lube

[Image: 2011-09-03132047.jpg]

Cams going in

[Image: 2011-09-03143106.jpg]

Had a problem with the cam belt running to-wards the outer edge of the cam pulleys so i had no alternative but to remove the lower belt cover to see why it was doing this?

[Image: 2011-09-03163741.jpg]

After removing the timing belt tensioner and tensioner pulley, several times, and finding no apparent problem it eventually seemed to run ok in the middle of the cam pulleys, im not too keen on leaving things like this as there must had been something out of alignment but its ok now so i pressed on and refitted both covers and the crank pulley, and its just dam handy having the right tools for the job, my Crank holding tool coming in dam handy, lol

[Image: 2011-09-03170735.jpg]

End result from day 5 is the engine and box are ready to put back in on Monday, im having tomorrow (Sunday) off, lol

mark3

23-07-2018, 10:55 AM #8

Gord Nice one, love seeing people do all the work them selfs :kiltsmilie:

Keep the pics coming

Block ready to accept the head with Cometic 1.4mm mls gasket in place

[Image: 2011-09-03125833.jpg]

Head on, torqued down to 90lbft in 10lbft stages from 30lbft using ARP stud/nut and the supplied molly lube

[Image: 2011-09-03132047.jpg]

Cams going in

[Image: 2011-09-03143106.jpg]

End result from day 5 is the engine and box are ready to put back in on Monday, im having tomorrow (Sunday) off, lol

mark3
Member

187

25-07-2018, 10:47 AM

Stevieboy Mark, your signature is out of date again. nicker:

Not till Sunday, lol

Anyhow, Day 6 and the engine is in! :cheeky: Hoorah!

Started the day (well started at noon) by rebuilding the n/s inner CV that fell to bits on engine removal, all the balls fell into the gaiter!

****** rubics cube got nothing on these, lol, then after a shed load of grease fitted it back onto the drive shaft and bolted the flange back onto it to stop it from happening again.

[Image: 2011-09-05132406.jpg]

Next up was getting the dam engine and box under the car, this took about 45 mins using the engine hoist to lift the gear box end and using a crow bar to move the sump across the ground at about 2" to 3" at a time.

[Image: 2011-09-05142935.jpg]

And hey presto, its in!!

[Image: 2011-09-05151615.jpg]

Then after a short break i cracked on and got all the cross members and engine mounts done, suspension and drive shafts in and bolted up, prop shaft on, exhaust on and wishbone support bolted on, gear lincages done, gear box oil cooler pipes done, fuel pipes done and clutch hydraulics done and bled, the clutch feels surprising light considering how heavy the spring in the clutch cover is.

[Image: 2011-09-05180633.jpg]

Weather is meant to be sh!te tomorrow but for now im well happy.

p.s. although this is actually quite possible to do by ones self i defo wouldnt recomend it :no: Big Grin

mark3

25-07-2018, 10:47 AM #9

Stevieboy Mark, your signature is out of date again. nicker:

And hey presto, its in!!

[Image: 2011-09-05151615.jpg]

Weather is meant to be sh!te tomorrow but for now im well happy.

p.s. although this is actually quite possible to do by ones self i defo wouldnt recomend it :no: Big Grin

purplewitch
Posting Freak

3,953

25-07-2018, 11:11 AM

#10

You make it look so quick n easy ... I shall start questioning my mechanic as to why it took longer than your twenty mins lol .. wtg you Smile

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purplewitch

25-07-2018, 11:11 AM #10

You make it look so quick n easy ... I shall start questioning my mechanic as to why it took longer than your twenty mins lol .. wtg you Smile

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