The Missouri Project

[tsi_tom]

Did cleaning it again take the paint off? Some machine shops use some pretty aggressive chemicals to do cleaning ...

 

No it didn't. They didn't use the spray cabinet. The spray cabinet has the harsh cleaning solution.

[tsi_tom]

I had the motor ready to be reassembled when I noticed a valley at the top of the number two cylinder wall. I didn't see it before but this caused me concern because the valley is right at the top where the ignition would take place. The machine shop wanted to bore it originally but said I would probably be ok.

 

So now the motor is back at the machine shop to be bored out. They will rough bore it and then let me know what size pistons I need to order.

 

This is my third trip to the machine shop. Third time's a charm!

[tsi_tom]

While I am waiting for the block to be bored I moved to the fuel system.

 

The car has been sitting for a long time. I am sure the gas tank looks bad so....

 

I bought this awesome gas tank from MotoCam360 and replaced the pickup filter and the conical filter.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Gas%20Tank/gastank_zps44bfa8d5.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Gas%20Tank/gastankpickuptube_zpsb0d3c30e.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Gas%20Tank/gastankinside5_zps4d6348b3.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Gas%20Tank/gastankinside4_zps7ebb117a.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Gas%20Tank/gastankinside2_zpsb8047127.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Gas%20Tank/gastankinside1_zpsd327fed9.jpg

 

Attached the new filter

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Gas%20Tank/newpickupfilterinstalled_zpsaa9930f0.jpg

 

Replaced the conical filter. This is a little unusual as the filter doesn't fit all the way into the pump. I need to look at the parts manual again.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Gas%20Tank/conicalfilterpartnumber_zps70fe1ee1.jpg

 

Buttoned up the tank for a later install. You can see their is a bent flange on the side of the tank even though the tank was packaged very well before shipping.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Gas%20Tank/filltubeopening_zps9737e9b2.jpg

 

All done

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Gas%20Tank/filltubeopening_zps9737e9b2.jpg

[tsi_tom]

Got the block back from the machine shop. This is the third trip to the machine shop. Last change is to have the cylinders bored 20 over

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Back%20from%20the%20machine%20shop%203/Sideofblock3_zps9ee1b4fa.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Back%20from%20the%20machine%20shop%203/Cylinder4_zpsa8bad3c4.jpg

 

Also I got the exhaust manifold shaved

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Back%20from%20the%20machine%20shop%203/ShavedExhaust2_zps5579220f.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Back%20from%20the%20machine%20shop%203/ShavedExhaust1_zpsc2153ec5.jpg

 

And now to install the forged pistons!

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Back%20from%20the%20machine%20shop%203/WisecoForgedPistonandrod_zps5bcd0105.jpg

[randy]

Man the block looks good what kind of paint is that painted with?

[tsi_tom]

Man the block looks good what kind of paint is that painted with?

 

I used Duplicolor Cast Iron.

[tsi_tom]

Reassembly

 

Pistons installed

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/Finishedtopofblock3_zps09b85f20.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/Finishedtopofblock1_zpsea2a8364.jpg

 

 

 

Checked the rod journals with plastiguage

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/Platiguageofthepiston2_zps72a84357.jpg



Reinstalled the oil pump. I am not sure how the cradle for the cam gear got so bent.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/Oilpumpinstalled_zps7f9d8241.jpg

Edited March 31, 2015 by tsi_tom

[tsi_tom]

I had to make a decision today if I was going to use the balance shafts. After thinking about it for a long time, taking into account the engine's previous condition, the balance shaft journal surfaces, talking to a lot of experienced people, and talking to the machine shop I decided to keep them. The machine shop had already installed new balance shaft bearings on the first trip to the machine shop.

[tsi_tom]

In the past I bought two intakes with injectors that were said to run fine.

 

I sent the injectors from the two intakes to https://www.rceng.com/

 

RC Fuel Injection called and said three were leaking externally. Only one black injector was good to start the cleaning process.

 

Here is the report. I find this amazing. It is no wonder why some Conquest/Starions don't run correctly.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Fuel%20System/ConquestBlackInjector_zpse777a7a2.jpg

 

The injector looks great!

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Fuel%20System/blackfuelinjector2_zpse16bf6f7.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Fuel%20System/blackfuelinjector1_zpsa60c4be1.jpg

 

Three externally leaking injectors

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Fuel%20System/Threeexternallyleakinginjectors_zps9b3ec1d7.jpg

 

What I have to rebuild. Looks like someone used JB Weld on the green injector.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Fuel%20System/originalenginegeenfuelinjector_zps2ff6a97c.jpg

[techboy]

I had to make a decision today if I was going to use the balance shafts. After thinking about it for a long time, taking into account the engine's previous condition, the balance shaft journal surfaces, talking to a lot of experienced people, and talking to the machine shop I decided to keep them. The machine shop had already installed new balance shaft bearings on the first trip to the machine shop.

 

Tom if you change your mind about those balance shafts let me know ... I have a spare elimination kit laying around. I have them eliminated on my Quest and my Eclipse. Don't even notice it on the Eclipse. On the Quest you get some vibration. My eclipse balance shaft seized, snapped the belt and caused a whole mess of damage this time last year. Pretty much made my desicion for me. Here's a post I put about it here:

 

http://www.starquestclub.com/forum/index.php?showtopic=131581&hl=

[mistapickles]

I had to make a decision today if I was going to use the balance shafts. After thinking about it for a long time, taking into account the engine's previous condition, the balance shaft journal surfaces, talking to a lot of experienced people, and talking to the machine shop I decided to keep them. The machine shop had already installed new balance shaft bearings on the first trip to the machine shop.

Great decision to keep the shafts, you'll be happier with the drive and performance. All in all looks like a top notch build you have so far...

[tsi_tom]

Tom if you change your mind about those balance shafts let me know ... I have a spare elimination kit laying around. I have them eliminated on my Quest and my Eclipse. Don't even notice it on the Eclipse. On the Quest you get some vibration. My eclipse balance shaft seized, snapped the belt and caused a whole mess of damage this time last year. Pretty much made my desicion for me. Here's a post I put about it here:

 

http://www.starquest...topic=131581=

 

Thank you for the option. Greg from the machine shop said that the 2.0s do have the bearing shaft bearing issue.

 

Great decision to keep the shafts, you'll be happier with the drive and performance. All in all looks like a top notch build you have so far...

 

Thanks for the compliment!

[tsi_tom]

I started to clean the oil cooler today.

 

Following the instructions from Starfighterpilot: http://www.starquest...hl=+oil +cooler

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Oil%20Cooler/oilcoolerflush_zps127f1995.jpg

 

I filled it a couple times with keronsene, shook it up, and dumped it out. There was some debris. The pot was cleaned before I dumped out the kerosense.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Oil%20Cooler/debrisinpan_zps271c9bdb.jpg

 

I then blew out the cooler with compressed air. Here is the result:

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Oil%20Cooler/debrisinpan4_zps21aec25e.jpg

 

Metal in the oil cooler:

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Oil%20Cooler/debriscloseup_zps27c4ec0d.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Oil%20Cooler/debrisintowel_zps6a307da0.jpg

 

The oil cooler needs to be cleaned out when doing a rebuild. You don't want that going throught the oil system on your rebuild.

 

Now I am soaking the oil cooler in kerosene overnight.

[importwarrior]

That is exactly what happened to GreenStar's car. put in new engine and

never cleaned the turbo or oil cooler out. it then killed the new engine in short time

right after he sold it..

[tsi_tom]

That is exactly what happened to GreenStar's car. put in new engine and

never cleaned the turbo or oil cooler out. it then killed the new engine in short time

right after he sold it..

 

Getting the metal particles out is turning out to be a big job. I have spent about 2 hours now flushing with kersosene and compressed air. I think I will switch to hot water tomorrow.

[techboy]

Not sure how I missed this step in my own build, but I'm glad I read this thread Tom b/c I was planning to start the car for the first time in 17 months this Saturday. I think I'd better take my oil cooler off and do this too. Don't want to destroy my own build.

[Convette]

I would just buy a new one, too much effort goes into putting a motor together to have problems later because of this. I wouldnt risk it. The engine looks awesome btw, very nice work.

[tsi_tom]

I would just buy a new one, too much effort goes into putting a motor together to have problems later because of this. I wouldnt risk it. The engine looks awesome btw, very nice work.

 

This is what I am going to do. It is just too risky with all the money and time into the engine. I might try to get a used one that has a known history and then flush that one if the stock one is expensive.

 

Thanks for the compliment on the rebuild!

[mistapickles]

Mishimoto sells universal kits for $200... I would go for the complete security of a brand new one... looks like too nice of a build to wonder.

[tsi_tom]

I worked on cleaning and painting the timing cover this weekend.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/timingcover3_zps2dadda21.jpg

 

Painted with Duplicolor cast aluminum

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/paintedtimingcover_zps15a85c83.jpg

 

 

I soaked the valve cover in Simple Green. I did this also for the timing cover.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/soakingthevalvecover_zps4b959832.jpg

 

Clean valve cover. Not sure if I am going to polish it. I kinda like the flat gray look.

 

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/valvecover_zpseff641cb.jpg

 

 

 

I removed all the paint off the oil pan. The oil pan was a bit rusty. All this cleaning is taking forever.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/oilpan_zpsdd01287c.jpg

 

I am getting antsy to finish this project.

[techboy]

Hit that valve cover w/ that cast alum color Tom and it will look awesome! Lookin good!!

[tsi_tom]

I took apart the turbo

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/12ATeardown_zpsabc8d36e.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/Cartridgeparts_zpsb22c2d60.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/turbinewheel_zps66164fc4.jpg

 

Looks like an oil leak was present. I wonder how much oil sticky stuff is in the intercooler.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/oilycompressor2_zps0a25d34e.jpg

 

Oily

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/oilycompressor3_zps6de3125b.jpg

 

Bought the Kamak rebuild kit. Here you can see the part number

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/kamak12apartnumber_zps700fab21.jpg

 

What is in the kit

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/kamakrebuildkit_zpsfcdd454f.jpg

 

Two nuts come in the kit but they don't fit. I contacted Kamak but they didn't respond. I reused the stock nut.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/turbonuts_zps62031d0b.jpg

 

One of the studs was chewed up so I fixed it.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/messedupturbinestud_zpsd7633e95.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/tappedtheturbinehousingexhaust_zps66354c37.jpg

 

I had some junk in the water jacket of the cartridge. Someone is using tap water.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/gunkinthewaterpassage2_zps0409c1bb.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/gunkinthewaterpassage1_zpsdbcd5aed.jpg

 

Cleaned up the oil ring groove

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/Cleanupoftheoilringgroove_zps16bb3f3a.jpg

 

 

All cleaned up and ready for reassembly

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/Cleanedupparts_zps342b9a69.jpg

 

You need these pliers to get out and install the clips in the turbo. This is the Proto J390 snap ring pliers

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/Protosnapringpliers_zps961e673c.jpg

 

Put some thread locker on the shaft so the nut doesn't come off

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/threadlockerforthecompressorwheel_zps5b0292d6.jpg

 

Finished cartridge

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Turbo%20Rebuild/completerebuiltcartridge_zps9dae19aa.jpg

[tsi_tom]

Techboy scared me with his oil pump gasket situation so I took my oil pump off to double check and make sure I had the tear drop gasket.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/oilpumpgasket_zpsb1e9d1f5.jpg

 

I got the PCI timing set for the crankshaft and balance shafts

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/timing%20assembly/pcitimingkits_zps88d2bacf.jpg

 

Turns out I didn't know how to tighten the balance shaft bolts

 

http://www.starquest...opic=137709&hl=

 

Made sure I had this washer against the guide.

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/timing%20assembly/balanceshaftguidewithlockwasher_zpse4e00040.jpg

 

And all the plated links lined up with the timing marks on the balance shafts and crank gear

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/timing%20assembly/upperbalanceshafttimingmark2_zpsbcfd2bbb.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/timing%20assembly/lowerbalanceshaftmark_zpsc2fbcdc9.jpg

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/timing%20assembly/Crankshaftmark_zpsfc8e83e5.jpg

 

Checked for alignment

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/timing%20assembly/inlinemeasurement_zpsaf622d2f.jpg

 

Assembled

 

http://i1069.photobucket.com/albums/u467/tsi_tom/The%20Missouri%20Project/Reassemble%20of%20the%20engine/timing%20assembly/timingfront2_zpsb8e82013.jpg

[techboy]

And you got the woodruff key on the oil pump too right?

 

Looks good. Don't forget to double check the tolerances on the timing chain tensioner compared to the FSM after the cam sprocket is bolted up. It's tough to see in the picture with the balance shaft chains on there, but it looks like it's out really far right now. It'll pull back in more once it's bolted up on the head.

[tsi_tom]

And you got the woodruff key on the oil pump too right?

 

The keys are all there. They never came out of the grooves. Today I should be putting on the timing cover, oil pan, and head.

 

Good luck on your car today!