Robokill 1984 Levin Coupe 8A9 // building new engine

[robokill]

Ok 3 weeks ago I decide to stop trying and get it trough MOT. Simple take out the old engine and build a new one. Engine is still in atm to move the car around where its stored. But I began taking apart the lower block which was originally in the car.

Then after some taken apart you come to the point where you have to take off the timing belt pulley. Which is always a pain the butt. But after some thought and deciding to take a new oil pump I managed to use it as a "pusher"instead of a puller. ( I borrowed a puller which of course didn't fit, go figure)

So I made some pictures because it actually went off pretty easy. Had to be a bit secure not to break it or my screwdrivers.

I first used two screwdriver between the lower block and the oil pump. Then behind the pulley itself.


PS don't look at the mess. I will clean it after the blue one is on the road

[Okami]

Nice man! As you can see... You can do everything man Everything is coming along nicely!

[robokill]

K lets sum up:

Engine is a lowerblock model nr: 10 (yes there is a model number on the 4age lower blocks)

- 40mm crank
- bore looks original (looking if I can do with honing only instead of oversize)

I will polish the lower block from the inside and remove any obstacles in the oil channels (there are some always from factory)

- rebuild lower block with new bearings and if needed new pistons. (rings etc)
- new oil pump

Lower block shouldn't take too long to refurbish.

Head: head was damaged and that has been fixed. Port polish as been done and I still need to get my new bronze valve guides installed and the new valves with a 3 angle valve job.

Some uprated valve springs and seats for the near future. Then I will mount the standard cams to start and end with some nice high duration ones.

[slowboy2]

i have new bearings for sale. :wink:
http://www.aeu86.org/viewtopic/ae86/t/92...sc/start=0
it is for original bleutop.

[robokill]

Well I ripped it apart completely and got scared while doing. I had a second look at the crank bearing caps..... They where mounted wrong.

As far as I know the bearing caps go from the front of the engine (where the pulley is to the back) in numeric order. So bearing cap 1-5.

This one had bearing cap 2 installed on the front and 1 on the second spot ?

So, I started with the oil canal on the second cylinder. I talked with many people about the 4age over the years and heard that the polish of the lower block is very good for the oil function in the engine.

Therefor I started grinding the walls and removed all the up and downs from the oil canal. I am nearly done with the second compartment. Then I will do the 3rd and as last the 1st and 4th.

So far I am thinking of doing a quick simple polish. Lower block will go to the engine wash shortly after being measured and hopefully honed. (instead of overbored)

[robokill]

recharged my digital camera to make a better shot. My problem is I use a battery powered tool. Which runs empty

[robokill]

Well all 4 are done. Now I am perfecting it to make it even nicer. With a grind tip its pretty rough so I am trying to make it as smooth as possible.

Also I am trying to go for a custom oil pan to try and increase the strength of the lower block. But I have yet to find a good design (looking at a dry sump strength but then a wet setup)

[Roger]

its looking very good Len keep up the good work
btw do you want a bigger oil pan?

[Ivan141]

I dont see why you would bother with a custom oil pan for a relatively mildly tuned engine. Way too much bother.
Polishing the internals is a good idea.. me thinks you need to switch over to sanding flap discs to get the surfaces smoother. The idea is to get it smooth enough for oil mist to cling to it easily, but you know this. Also invest some money in a better windage tray + crank scraper if you are serious about reducing windage losses, they do a better job than polishing alone (and polishing is much more work).

[robokill]

good point Ivan. Though I am not too fond of the crank scrapers. Don't really trust them in some way. I am working with a sort sanding blocks to smooth the last part.


Roger: yes making a custom oil pan I will also make it bigger and use different mounting points for oil cooler and oil temperature senso

Regarding mildly tuned Ivan. I tend to push this engine between 185-200 crank hp. So I personally wouldn't call it mildly. With a good lower block and a good head with good cams exhaust and ITB's I should manage that amount of power.