Project Engine Rebuild- Vtr 1.6

[gretsch-drummer]

Right then (copied over from forums), was on the look out for a decent TU5 (8v 1.6) engine as a little project for when I want to replace the one in my 306.

Luckily I spotted a 82k VTR engine on ebay so placed a bid.....next thing I know, I've won the engine for a WHOPPING £25!!! Went and collected it that evening. Only had to travel 20 miles for it (Leeds to Normanton) but the drive home was a VERY slow one as even though I ratchet strapped it to the rear seats, it was leaning over more and more. When I did stop to re-tighten it....it had already emptied ALOT of oil into my boots rubber tray thing (thank god I had one of those in there)

Anyway, here it is after making a base to wheel it down the drive on:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0402.jpg


Just to point out, I've never done anything like this before. So it's all a big learning curve.

Later that night I got onto stripping the engine of what I could:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0404.jpg


Yesterday I managed to whip the head off and borrow a valve spring compressor and big socket set to get the cam pulley off. Was a right ballache with the spring compressor (not the correct one tho), the spring cap didnt always seat onto the spring properly.:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0410.jpg


So after getting everything off and loosing one spring retainer as it pinged off somewhere in the shed (can't find it) I was left with a bare head:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0412.jpg

http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0413.jpg


Then tonight I thought I'd clean the valves up a bit. I put them in a drill and used some WnD paper with carb cleaner as lube:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0414.jpg

http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0419.jpg


Bit of an update:


Was looking on gumtree yesterday...and wouldn't you know: Someone had just put up a engine stand for sale. £25 Bargain!.

so whacked it on the stand today and got busy:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0425.jpg


Had to get dads mate round with a breaker bar to get the crank pulley bolt out so managed to get everything dismantled:
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/431457_10151392414650526_581790525_23149884_104937 8111_n.jpg


So, found a place near my college that skimmed heads:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0440.jpg

For £25!!!! Top fella' who sorted it, was able to drop it off at 12 and I picked it up at 4 after college.

For anyone in Leeds wanting it done the place is called "Leeds Engine Exchange"

Went and bought a lapping tool and paste and got busy re seating the valves:

Before:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0443.jpg

During:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0444.jpg

After:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0442.jpg

Cracked on and painted the block etc up. No fancy colours here:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0447.jpg

http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0433.jpg

http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0434.jpg

Then decided to do a bit of port polishing after alot of umming and arring:

Exhaust ports:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0467.jpg

http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0470.jpg

(havnt got a finished picture but I went over with a fine dremel wire wheel and 600,800 and 1000grit wet n dry, came up pretty smooth)

Inlet before:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0483.jpg

During:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0484.jpg

After'ish (not latest picture)
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0485.jpg

Also done more polishing with 600,800 and 1000grit paper, but no pictures.

[gretsch-drummer]

Had delivery of an 106 S1 manifold:

http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0494.jpg


Whacked a bit of primer on ready for gloss black:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0495.jpg

http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0499.jpg


just been doing a bit of work on the inlet mani and throttle body.

Cleaned up and polished the ports (only as far as i could reach with my fingers tho) with 600, 800 then 1000grit wet and dry:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0512.jpg


I needed to blank off the stepper motor hole as my 1.6 uses an Idle Control Valve which I'll be drilling and tapping a hole into the plenum of the inlet:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0513.jpg


Next I need to cover up the hole that feeds the stepper motor inside the TB:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0515.jpg


And that is where I am at as of tonight (26th). Need to sort out a bracket for my ICV and drill in a hose adapter into the side of the manifold so the ICV can get plumbed in.

Then it's onto the bottom end rebuild: Piston rings, crank bearings, big end bearing etc.

Cheers!!!

[jeffchiz]

is it staying a relitively standard engine with a s1 rallye inlet? or are you going to be putting an after amrket cam in there?

good progress interesting to read :y:

[gretsch-drummer]

hey, yeah I'm planning on a nice 4-2-1 or 4-1 (saxo and 106 manis go under the subframe but 306 exhausts run over the subframe, so if i find a vtr mani I'd need to shorten it and put a bend into it etc.) Then eventually a nice cam and pulley, nothing too lairy as I don't really want to spend £200+ on a remap etc atm.

But finishing the inlet is next then start on getting the parts for the bottom end soon.

[jeffchiz]

sounds good, what engine do you have in the 306? any pics of it?

[gretsch-drummer]

I have the same TU5 1.6 in atm, so just doing a straight swap. Staying with the good ol' 8v Team:

http://i153.photobucket.com/albums/s206/DTurboTom/sheff%20pug%20meet%20dec%202011/IMAG0120.jpg

[CJMackin]

That 306 looks class mate. Loving how you jumped in at the deep end learning with the rebuild too, and the bargains your getting!

[gretsch-drummer]

Aye, best way of learning is 'Doing'. Just looking out for a exhaust mani next

[Gandi699]

This looks great, nice attempt on your first go. Bet that valve spring compressor was a pain being so small, I had to go get a big one when I did my valves as I couldn't push the lever on the small one

[S666UKH]

looking good mate.

[mlawlan69]

looks great got big ballls to just jump in like that and do it!

where in leeds are you from?

[gretsch-drummer]

Im up in Moortown, you anywhere near?

[mlawlan69]

Very ha, other side of the ring road in adel :-)

[gretsch-drummer]

Ahhh, Good road is that ain't it, good place for a blast. But going from adel to moortown ain't so good when there's standing water on that little dip on the ring road.

[mlawlan69]

haha yeah, i like to go the back route down stair foot lane if i have more time, such a fun road :P

[gretsch-drummer]

Hmm, just google mapped it and I've never been down there. Will have to give it a look.


(dammit, why arn't my posts counting up.....I'll never be able to see the for sale thread at this rate ha)

[saxosteve12]

Hmm, just google mapped it and I've never been down there. Will have to give it a look.


(dammit, why arn't my posts counting up.....I'll never be able to see the for sale thread at this rate ha)

i think they suddenly go up cos mine didnt move for ages then i was at like 40 something lol

also kudos on the engine job would love to do it :y:

[Jay_]

post count doesn't go up in this section.

Rebuild is looking good. love how everything is costing 25 quid!

Pics of you gretsch kit? how long you been playing etc? i'm a drummer too :A:

[gretsch-drummer]

Ah cheers Jay, yeah everything is £25 if you look hard enough! Ha

(sorry about the spamming of my own thread)
Been playing for about 10 years now. Gretsch Renown Maple:
http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/251998_10150735284750526_581790525_19906686_390134 4_n.jpg

[gretsch-drummer]

Well a bit has happened on this.

Managed to get the inlet drilled so I can use my ICV from the 306:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0564.jpg

http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0565.jpg

Also bought a 4-2-1 mani the other week:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0570.jpg

Just need to get my mate to chop and weld it to fit the 306 as my exhaust system goes over the subframe instead of under like the mani does.

Rebuilt the head back up:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0568.jpg

Then did a little mock fit of everything:
http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0573.jpg

Decided to just get the head whacked on the original bottom end, its only done 85k so still good for a while longer.

[Ali123]

im thinking of doing the same thing mate, but abit difficult to spare some monies while saving up for a new car but good stuff mate :)

[gretsch-drummer]

^Aye, just hold out long enough, a good deal will always come up for parts etc

[Ali123]

just had a quick look, found a couple for 50 quid on gumtree, just cant afford it atm haha but its definatly on the card, just to play around with and learn from it

but good work anyways fella

[sam_16v]

just had a quick look, found a couple for 50 quid on gumtree, just cant afford it atm haha but its definatly on the card, just to play around with and learn from it

but good work anyways fella

damm thats a shame my mate just weighed in a vtr engine only had hg failure could of had it for free aswell

engine build looking good mate

[Ali123]

damm thats a shame my mate just weighed in a vtr engine only had hg failure could of had it for free aswell

engine buildd looking good mate

oh man! even if its a fucked engine like, just to mess around with!

anyways not to thread hijack so yeah! :y:

[gretsch-drummer]

Update:

Decided to whack the S1 inlet yesterday and see how it all runs etc. Will prob be getting the head swapped over in a few weeks.

http://i60.photobucket.com/albums/h19/gretsch_drummer/IMAG0638.jpg

Buying a proper pipercross jobby in a couple days, then I should be able to sort out the ICV hose (as currently its just placed behind the headlight with a pair of tights taped over the end)

Runs perfect with a 800-1k idle.

But I did have one problem with my DIY catch tank, it didn't vent enough so a bit of oil got blow out the dipstick pipe. So will be putting a breather filter on the catch tank aswell.

[Bedford126]

Mate if your blowing oil out of the dipstick tube then you don't have anywhere near enough flow through your catch tank a filter won't help.

Also did you get into Leeds tech for paint spraying?

[gretsch-drummer]

hmmmm, well then.....Ebay catch tank it is.

I've got my 'taster' week in mid August so will find out around then I hope.