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Old 7th June 2015, 13:43   #81
Chris245
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Rebuilt the oil pump...







All clean ready for assembly...
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Old 7th June 2015, 13:48   #82
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Modified the ARP rod bolts and assembled the pistons/rods after a final clean...
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Old 7th June 2015, 13:56   #83
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Prepped the block...

After a skim...





Then a flex-hone..



Before...



After...



Then a final clean and a quick paint...









Finaly some fresh core plugs...
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Old 7th June 2015, 14:06   #84
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Then I started to assemble the bottom-end...









Checked the clearances...



Torco assembly lube...





Crank in...



Pistons installed...





Big end clearances...







All torqued down...



Oil pump fitted...
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Old 7th June 2015, 14:16   #85
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Covers and crank pulley painted...













Sump painted...











Engine on its new stand...



Sump fitted...
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Old 7th June 2015, 17:49   #86
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Next up was the head work.

Started by machining the head to fit the saxo plenum...







Then ported it.

Inlet...





Exhaust...





Polished and blended the chambers.

Before...



After..



Finally lapped all the valves in before giving it a final clean...



All clean ready for assembly...





Valves in with new stems seals...



JP4 spring platforms with J4 springs and retainers.



New head gasket...



All bolted down...



J4 hydraulic lifters...



705's...



ARP ladder bolts...



All bolted down...







Cam covers on...
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Old 7th June 2015, 17:58   #87
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Finally it was just timing belt kit and a few other bits.





Oil pressure sensor sender...







All done...
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Old 8th June 2015, 09:03   #88
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Awesome work.

Only thing I'd suggest is ditching the socket caps you have on the JP4 cam covers for the correct hex head items from Citroen. Even with a washer, the socket caps don't clamp the covers properly and you end up with leaks.
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Anyhow I only live my life a cup of tea at a time and im all out so im off to boil the kettle
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Old 8th June 2015, 20:44   #89
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Great thread mate! thanks alot. Just started stripping a vtr for fun and hopfully go along the same engine building line as you are now!

Can i ask why you machined the ARP rod bolts?
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Old 8th June 2015, 23:21   #90
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built in a laboratory !

epic build mate keep it going!
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Old 9th June 2015, 18:33   #91
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Quote:
Originally Posted by Liam_ View Post
Awesome work.

Only thing I'd suggest is ditching the socket caps you have on the JP4 cam covers for the correct hex head items from Citroen. Even with a washer, the socket caps don't clamp the covers properly and you end up with leaks.
Thanks mate, I'll keep an eye out for leaks. They seemed ok on the J4 though.

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Great thread mate! thanks alot. Just started stripping a vtr for fun and hopfully go along the same engine building line as you are now!

Can i ask why you machined the ARP rod bolts?
They have to be machined so they sit flush against the rod...



You'll see when you get the rods out the VTR engine.

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built in a laboratory !

epic build mate keep it going!
Thanks mate.
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Old 9th June 2015, 23:36   #92
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Wow!!! Excellent work!
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Old 10th June 2015, 10:57   #93
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Quick question I was considering taking a 16v engine from a 1996 saxo and putting it in my 2003 1.6i 8v saxo. Will it fit ??


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Old 10th June 2015, 10:57   #94
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Cool project btw


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Old 13th June 2015, 22:20   #95
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Great work love the photos.

Wish I had the space and cleaniness of your workshop.
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Old 14th June 2015, 01:55   #96
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looks great i need those carbon door cards in my life
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Old 24th June 2015, 18:23   #97
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Some of the progress we made over easter...

Fuel tank cleaned and refitted..





Ran all the rear brake lines before fitting the rear beam...







I didn't get many pics of the next bit but we refitted the rear beam and got the engine out.

The car then looked like this...



We then degreased the engine bay, ground back any rust and patched up under the fusebox where there was a hole. We also prepped the front arches...





We then got the engine bay painted and the arches undersealed...









Then, we got a bit carried away with the heat protection...
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Old 24th June 2015, 18:37   #98
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Great project where did you get the arp ladder bolts from?
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Old 24th June 2015, 19:44   #99
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Great project where did you get the arp ladder bolts from?
They're not saxo specific mate, just ordered some arp m6 bolts to the right length.
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Old 24th June 2015, 19:56   #100
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gold engine bay looks mint
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