My silver RS2 Project

[Tractor Dave]

My clutch arrived. Looks good.


And I found a piston. Hurray.


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[Shenkm87]

Some amazing progress!! Good luck!

[Tractor Dave]

Piston arrived. It's in excellent shape.


So I wasted no time. Ring gaps were checked.



All were in spec and I didn't need to file any.
Then I got cracking.








Everything went smoothly despite using cheap ring pliers and ring compressor.
I've used assembly lube in all the bearings.


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[Tractor Dave]

The pick up got a really good clean. There were a few lumps of hard black plastic in there.


And the sump got a final clean.


I'm using a belt and braces approach to sealing. This stuff is a good way to provide some extra sealing.


This little o ring isn't in the full gasket set. I happened to have a new one in my parts stash.


And we got busy.

Small allens 10nm and the three larger bolts 20nm. Tighten in stages and in a diagonal pattern.
The oil pick up bolts are 10nm. The longer ones have lock washers. I used a little thread lock on the other two.


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[ottawa coupe]

Hylomar is magic. I love it and use it on all surfaces now, gasket or no gasket. I had a 16vt race engine that i could not stop leaking at the valve cover. To the point of oil fire(s!!!!) At the turbo. Used this stuff, dry as a bone from then on.

[Tractor Dave]

I've done very little due to still not being 100%.
It's been very mild and damp so I wanted to get the engine block sorted before it starts rusting in front of me.
The oil pump housing and pressure senders got fitted. All the other holes into the block got sealed up before I started cleaning. The block then got a good wire brush and treated ready for paint.







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[Tractor Dave]

The block got some good quality engine enamel. I fired up my little heater to help warm things up first.



Then today I made a start fitting the head.
New gasket.

Some cut off old head bolts make a handy guide.

The head is nice and clean. New exhaust valve guides have been fitted and it's had new valve stem seals and a light skim.

On it goes.

New head bolts got a light coat of light oil.

Then torqued up in sequence.

Hydraulic tappet buckets were cleaned and oiled before going back in the same holes they came from.

Next job is the camshafts.


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[Tractor Dave]

Everything cleaned and lubed up nicely.


New chain.


And new seal.


Fiddly but got them lined up nicely.





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[4WDrifter]

Great progress Dave. It took me about 60 seconds to read about and view the pictures of a good few hours work there. Thanks again for taking the time to provide us with the photographic record.

[Tractor Dave]

You are welcome. After seeing the pics myself I went straight back out to the garage. The fourth pic makes it look like the cam timing is wrong, but its just the camera angle and taken before caps fitted. Gave myself a shock!

[Blagave]

Dave, you are a machine, just love your build threads.

[Tractor Dave]

Thanks. Enjoy yours too.

I gave the rocker cover a wash.


And fitted the cam position sensor and top pulley. Plenty of thread lock here and 65nm whilst pulley supported.



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[K Simmonds]

Great work there Dave, you've done a smashing job of that engine inside and out.

[5cylinderman]

Wow, is that the latest EFR turbo on the right???

[Tractor Dave]

Wow, is that the latest EFR turbo on the right???

Its the Welsh developed "Gwynt Poeth" special