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I stripped the heads the completely jet washed them and then put them on a heavy duty cycle on the old dishwasher i useas a parts washer.
The valve train is completely standard STI 5 with the exception of the springs which are RCMS WRC items. They are noticebly thicker to look at and much more difficult to compress.
The valves were reground with two types of valve grind paste harsh and then fine.
The heads were rebuilt but buckets and shims left off for the time being.
They were then bolted onto the head and torqued up inplace.
I did this in four stages 20ft/lbs, 40ft/lbs, 60ft/lbs, and finally 85ft/lbs.
They were left overnight and then re torqued in the morning.
Then all the valve clearances were measured with the heads in place and torqued down for greater accuracy. I was fairly meticulous with measurement and I even ground some shims down by hand on a wet stone. As a result the clearances weren't just within tolerance but they were all exactly spot on.
rechecked head stud torque after all tolerances were done.
The next job seemed quite tricky at first but after a fair bit of research the solution was quite simple.
I have a version 5 engine that was going into a version 4 car. That presented problems with the wiring loom and in partcular the Idle control valve which is completely different between both versions.
The version 4 manifold couldn't be put on as the bolts pattern on the heads is different. So I had to modify the version 5 manifold to accept the version 4 Idle control valve and version 4 throttle body.
I had to have a piece of billet aluminium machined to accept the valve itself and this in turn bolts onto the manifold.
A feed needed to come out of this into the manifold thus allowing air to bypass the butterfly valve on idle.
The manifold was drilled and tapped to allow ICV air to pass through.
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It was then painted and all the fuel rails, injectors (740cc), braided fuel lines, goodridge fittings and SX fuel pressure regulator were assembled.
From the front.
From the rear with rotated turbo bolted on
Engine Built
Last edited by dazdavies; 25 October 2008 at 20:53.
Next to be looked at was the fueling system.
I already had an intank 255lph Walbro but with the power i'm intending to run this wouldn't have been enough on it's own so a more robust solution was needed.
I decided to still retain the walbro and use it as a lift pump to a swirl pot which fed an inline Bosch 044 Motorports fuel pump. This installation solved two problems 1 it would produce the amount of fuel needed two, will prevent the dreaded fuel surge on demanding right hand handers.
So, we have the swirl pot and bosch pump installed in the boot.
This leads to the fuel rails via a Sytec billet fuel filter.
That's about where I am with it at the moment. I'll update as and when any progress is made.
Cheers
Daz
Last edited by dazdavies; 25 October 2008 at 21:07.
2 cans cost me £25, from ebay and I got a free bag of Haribo when it was delivered.
They delivered the very next day too. Can highly recommend these guys. eBay My World - camautodevelopments
2 cans cost me £25, from ebay and I got a free bag of Haribo when it was delivered.
They delivered the very next day too. Can highly recommend these guys. eBay My World - camautodevelopments
Ha ha, i've bought some stuff of these guys and i received a 'Wizzle Fizzle' lollipop whistle.
Swirl Pot was an ebay purchase and all the fuel lines and fittings were from Hose Direct in Harworth, Doncaster, 01302 746969
Paul the owner is a top bloke and does some fantastic prices.
.
one for the davies clan lol.
