| Work on the Engine. |
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| The lads. Beany, Me, Brother Roy and Galley. It's a heavy piece of kit with the gearbox and driveshafts still in place, and all pipes and engine mounts! Many thanks to Bob again for driving home very steadily with this great lump in the back. First job at home was to remove the 'box so the engine could be properly stood on the wooden frame and skateboard. Driveshafts were later removed to make storage and servicing easier. The wiring has been modified to suit a Mk2 astra already, but it's a bit of a mess, so i'll be re-making the looms soon. Apart from that, the engine doesn't need that much atention, it's got a genuine 60,000 on the clock, and is quite clean. I will be replacing timing belt, water pump and rollers, and all of the accessable oil seals... regardless of condition, i know sods law oh too well to be taking any engine-out risks! |
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| Gearbox removed, and engnine sitting properly. Have inspected the timing belt area, and everything seems very tidy. |
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| Engine loom: Where it passes through the bulkhead grommet, inside the PVC sleeving is a load of white gloop, like very sticky Blue-Tak. This is for waterproofing between engine bay and cabin. 30-01-04 |
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| First job was to figure out the wiring. Step1: label where connectors were unplugged from. Step2: go through diagrams observing wire colours to double check! 30-01-04 |
| The work on the engine will be split up into three phases: Phase 1: The Spripdown Phase 2: Pre-Preperation Phase 3: Assembly |
| Phase 1: The Stripdown |
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| After Stripping off most pipes, was left with a relatively naked lump.06-05-04 |
| Found problem... the numer 1 ext port bolts had been eaten therough by water leaking from the thermostat housing. See the top bolt stuck between ports 3+4. Bottom was awol. |
| Results from running without manifold not properly being bolted. must have been noisy... 07-05-04 |
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| Only when taking these ally parts off, you realise how lightweight they are! 07-05-04 |
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| Then off came the head... 08-05-04 |
| Everything looks in great shape, just a bit of a de-coke session needed. 08-05-04 |
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| Always nice to see the COSCAST mark. 08-05-04 |
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| Exhaust cam out. 08-05-04 Inlet camshaft also out on same day. |
| Bucket lifters out... Pistons rotate niceley, good sign of no rattle and tap... 09-05-04 |
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| Clutch off, home made braces on flywheel, and botton end bolt out. 09-05-04 |
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| Stripped down, the 2.0L block looks small, next is, paraffin and wire brush ready for painting. 09-05-04 |