Summeh's Head Rebuild

[arj256]

Once upon a time in a dark cold garage in Hampshire, Me (Adam) and Summeh (Matt) set upon rebuilding his head on Matts Williams.
Matt had been in the garage a few times before me preparing the car for the head to be put back on, so when i turned up we could crack on with the fun part.
I was set the task of making sure that the bottom end was nice and clean, this was what it was like after a quick going over:



Matt was trying to get Aux Belt tensioner pulley undone, and as we had a new belt we cut off the old one to make it easier to work with.
You can just see the pulley we was trying to undo:

Its the just off the picture, to undo it you had to put a 7mm allen key in the middle and turn it anticlockwise to undo it and then you used a 22mm spanner to adjust the pully for tension. As we was going to do this later we just took off the Aux Belt crank pulley so we could put the cambelt on.

With the pulley off we needed to get the old idler pulleys off, shown here: (The shiny looking pulley is the old one):
To get it off we needed to remove the plastic cover which was around it, to do this we took off the lower bolts which we could get to:

Once all the bolts where off you then need to remove the lower rear pulley so that you can take the plastic cover off as it gets in the way.
We found that instead of taking the plastic cover off, we could lever the plastic cover out enough so that we could take the pulley out :D Was a good shortcut.




We just slid the new one in and did up all of the bolts, it was suprising how worn the old one was, it made quite abit of noise when we spun it quick so it was worthwhile changing it. The Tensioner pulley had allready been put onto the head by Matt which was just a simple job of bolting it on.
So that was the new pulleys put on.

After another clean of the bottom end this was what it was looking like:
We didnt spend too much time taking all of the deposits off the top of the pistons but you can see where a cambelt snap had happened, and the valves had left impressions on the pistons:





Whilst i was messing around with the camera. I took pictures of the oil passageways which feed up from the sump into the bottom end, you can just see the light reflecting at the bottom:



Heres a pic of the conditions that we where working in:

When the battery died, we ended up running that light off my car battery.

Mid way through working we was distrubed by a scary looking person

Fortunatly we didnt see it for long so we could continue on with our work.

Heres a pic of the flywheel and the marks on the gearbox which we will follow when we time up the cambelt:


Now that the head was all cleaned up, we put the gasket onto the bottom end:

Before putting the head on we made sure that the pistons where all in the middle, just to be on the safeside in case a valve could come in contact with a piston at Tdc when putting the head on.

Here's a pic of Matts Cylinder Head which has some stuff done to it

We decided it would save time by putting the inlet manifold on before putting the head onto the bottom end. So we bolted it on and did it up, and then proceeded to put the head onto the bottom end making sure it was located via the dowels.



A pic showin the Cams with some Cam lube on it:


We then proceeded with greasing up the headbolts with the supplied grease in the pack and then followed the Williams tech manual which can be downloaded. We did it up in the order, and then loosened the bolts off and then re-tightened and then finally tightened with an angle gauge which was to 107Deg.
With this on we proceeded to put the rocker cover on:

We needed to have this on so that we could use the notches on the rocker cover for timing up the pulleys on the cams.

You can just see the nothces in that picture.

We Proceeded with feeding the belt around the pullys and over the tension/idler pulleys




With the belt loosely on we aligned the notches which are on the cam pulleys up with the notches which are on the rocker cover, and we used the lines which are supplyed on the cambelt to help us make sure that they where aligned right.
Then before putting the belt over the Crank pulley. we adjusted the flywheel by manually cranking it over so that the notch on the flywheel was inline with the '0' on the gearbox. Then we put the belt over the crank pulley which made the belt loosly tensioned over all of the pulleys.
Then we gave it some tension by adjusting a M6 bolt which we had screwed into the back of the head:

we gave it abit of tension as to make sure that the belt wouldnt come off. Then we cranked it over a few times by hand to make sure everything was fine.
Once we where happy that it was all timed up correctly, we gave it more tension so we couldnt turn the belt 90deg on the longest part.
Once we had done that, the timing part was over.


We then proceeded with doing a compression test to make sure everything was allright, we did this a few times and the engine span over fine comfirming that we had timed it up correctly.
Once we had done the compression test it was getting on and was pretty cold. So decided to call it a night.
After packing up i came to start my car, and had a flat battery from running the radio/strip light all night apparently the inverter we had been lent was supposed to warn you when your battery was low.
Apparently not lol.
All was fine after a quick jumpstart.

And that was the end of the night.

[VIPERONE]

nice one

[BenR]

goodwork guys.

Such a shame though, i wish it was up and running like the beast it will be.

[northy]

looking good guys - keep us updated with the progress !

[Mattie]

nice little insight that

[summeh]

yeah unfortunately the piston rings/bores are well and truely ****ed on cylinders 1 and 2. so comp figures not good... bottom end rebuild now.

[LEIGH-ANNE]

[Martin]

yeah unfortunately the piston rings/bores are well and truely ****ed on cylinders 1 and 2. so comp figures not good... bottom end rebuild now.

Just get a low mile meggy btm end..not seen a slow meggy btnm ended 2.0 yet.

[Fred]

i thought you weren't using the gold manifold because of the previous "issue"

[summeh]

i thought you weren't using the gold manifold because of the previous "issue"

I spent about 20 hours (in total) cleaning it. Don't think i ever said I wouldn't use it.