spent a bit of time assembling the piston/rod assemblies today.......

then i put the new piston rings on to the pistons with a specail tool for spreading the rings without breaking them

another top tip.. put the shell bearings into the conrod before you put the rod/piston in the cylinder block

using another special tool for compressing the piston rings whilst insertin them into the bores

my advice to anybody is to insert all the pistons at the same time to save keeping turning the engine over... i allways put them all in so they are all level with the deck like this.

after they are all in thier respecting bores, turn the engine upside down and fit the cap(also with a new bearing shell) onto the rod and tighten it down to the specified torque setting...

you may notice that i have temporarily re-used the old conrod/big end bolts, you should renew these every time they are undone because the tightening process stretches them, i've only put these back in loosely whilst i'm waiting for my new ones to arrive.

decided to fit the oil pump on today as well...

i had to find a suitable oil seal for it because the one supplied in the conversion gasket set was the wrong size... went to Brt bearings in portsmouth and it was like

right.... i'm going shopping tomorrow well.... scrapyard shopping anyway

i need

1) distributor from 6n polo

2) thermostat housing

3) 2.5 bar fuel pressure regulator

4) might see if i can get some polo rear stub axles/calipers for the rear disc conversion too

5) also on the lookout for a pair of front hubs so i can start looking at the big brake conversion.

i've ordered a piper camshaft as well, so that should be here in a few days hopefully

guess what.... they're here! but....... i've just had a quick look at them and one of the spindles is jammed so i'm gonna have to strip it down to find out what's wrong with it..... an no.... i'm not sending them back

problem solved.. a tiny burr on in the throttle bore was stopping it from opening..

woohoo! you have throttle bodies:D

and an engine looking a lot healthier:thumbup:

head goes on tomorrow hopefully

fitted the oil pick up pipe

then the sump, unfortunately the windage tray i bought doesn't fit this engine so it aint going in

after fitting the sump i quickly popped the head on and torqued it all down to the correct tension, 60nm +90 degrees +90 degrees

view from other side of engine

Looks great - keep up the good work

looking good, looking good.

bloody hell!

I'm hoping to pull the lump out my touring this weekend and tidy her up.

not opening her though-if it aint broke, dont fix it!

very impressed with the workmanship Tom

wow i have just read all that link took me an hour.

propper good dude:thumbup:

next job is to fit the coolant transfer pipe and thermostat housing

next i fitted the new water pump... part of the timing belt cover is also retained by the same bolts that hold on the pump so this goes on at the same time

next i fitted some new manifold studs. then the exhaust manifold goes on...

had some more goodies turn up today.

this kit is quite basic, it just contains the timing belt and tensioner

next spark plugs go in! then fuel rail and injectors

then the throttle bodies

here's a different view of the bodies, you can see that they have been drilled for fuel injectors then plugged, this is handy for me if i ever decide to fit another set of injectors

it's all coming together finally, starting to tie up all the loose ends now... i've even found a suitable fuel pressure regulator, came out of a mondeo with a 2.0 zetec engine..

camshaft not arrived yet but should be here tomorrow

WOW!

inspirational.-excellent work, I'm bloody jealous!

right then folks..... i'm off to skospares in poole......

update later

picked up a few bits and pieces today..

got a pair of front hubs, going to strip them down and measure them up ready so i can make up some brackets for the big disc conversion.

here is the right hand engine mounting bracket

the one on the right is the one for the 6n polo, the one on the left is for the felicia, you can see the similarities bewteen them, they both use the same mounting holes in the engine block

here is that bracket fitted to the engine block