top end strip down.

[diesel des]

Ok, i have a ABY that i am going to put into my UR. I got the engine, loom etc from a fella on ebay, a long time ago. It is supposed to have 60K miles, but i cannot confoirm that. So before it goes into the UR i am going to lift the head and have a look arround.

Now, my goals are to build a stroker eventualy with all the right bits, but this ABY is just to get the 20V going in the UR and to do a few years of weekend use till the stroker fund is up.

The list of stuff i have is,

RS tunning tube manifold.
Garrett GT30R turbo
Soon to have AAN intake
Large intercooler
ARP head studs
2 steel head gaskets
new T belt
New t Belt tensioner
new Water pump
7A cams
and a few other things i have forgot.

I am well used to working on engines, but never the 20VT. I have it on an engine stand. My plan is to pull the head and check all is ok, then lower the CR a little with the fat layer form the second head gasket. useing ARP head studs also. I will then fit the 7a cams etc. Would anyone recommend changeing the Chain also? Is their a service intervile on those? How do you measure for ware?

I plan on running this setup with a Custom chip, big injectors etc and i dont see why it cant do 400 BHP + with the torque limited to keep the rods safe.

What else would be recommended to change in the way of gaskets etc? thanks,des.

[Jeffer]

RS2 big-end bearings
Cam-/Cranckshaft seals
Maybe to be on the safe side a bosch 044 pump aswell as the camshaft chain. Chain costs about 40 euro's iirc.

Cheers

[diesel des]

Doesent the ABY use the ADU RS2 bearings? Thanks,des.

[S2central.net]

I'd recommend a Bosch motorsport fuel pump here... More headroom than the UR pump.

I would also go with a 3B flywheel for better throttle response and ability to rev - plus you'll mate with the UR's 016 box that bit easier using something like a Sachs motorsport spec clutch - they do one for a 3B. RS2 (Bosch Green) injectors will be adequate for 400bhp.

I personally wouldn't lower the CR at this time if your goal is 400bhp with a programmed ceiling on torque levels in the mid range circa 550Nm to preserve the rods.

In my opinion you will have plenty of scope for aggressive ignition timing - especially on a diet that contains healthy doses of Toluene !!!!!!!!!

Let me know if you need a hand... I have all the engine manuals and schematics for starters... and we haven't had that pint in Belfast yet

You'll be needing a fair bit of custom pipework along the way and an oil breather/cyclone wouldn't go amiss.

If you want to really get noticed - budget for a separate WG exhaust pipe as well :lol


Paul

[diesel des]

Yep i have a 3b flywheel getting a light skim as we speek. As for clutch i was in on the group buy and got the clutch net carbon unit, so that should be ok.

thanks for the offer paul, im sure i will take you up on that! A seperate wastgate pipe was in the plans too. I still need to get the bodywork sorted and sprayed, but thats not a biggie. As for pipework, that doesent put me off as i had to make all my own for my 230BHP DIESEL mrk2 golf.

[S2central.net]

Whats your target weight on the flywheel ?

Are you getting it dynamically balanced on its own or with all the rotating mass ?

Are you getting the machining done locally or on the mainland ?

The only folk I have ever entrusted such machining operations to are Bassett Down in Swindon. I certainly don't know of anyone in NI with the skills to lighten and balance Audi I5 cranks for example. Let me know if you've found a local expert that you trust these things to...


Cheers,

Paul

[diesel des]

Paul, im only getting 0.2mm taken of the friction surface of the flywheel to make sure its smooth and true for the new clutch. I dont what to screw with ligtening it due to the ballance issue. But a light skim will be fine. A local machine shop is doing it. I had to remove all the timing dowles and broke 1. So he is removin that to.

I took the exhaust and inlet manifolds of last night. i will put them up on ebay soon along with the turbo. Then maybe at the weekend i will lift the head. Thanks,des.

[auditude]

Paul, im only getting 0.2mm taken of the friction surface of the flywheel to make sure its smooth and true for the new clutch. I dont what to screw with ligtening it due to the ballance issue. But a light skim will be fine. A local machine shop is doing it. I had to remove all the timing dowles and broke 1. So he is removin that to.

I took the exhaust and inlet manifolds of last night. i will put them up on ebay soon along with the turbo. Then maybe at the weekend i will lift the head. Thanks,des.

Des,

Interesting project, I'll be watching your progress.

Isn't there only one timing dowel, at 62 btdc? The other ones are to position the pressure plate, and the two long ones that are supposedly only for diagnostics on the assembly line.

Ken

[diesel des]

It is one of the Long ones i have broke. Then their are 3 for locationg the preasure plate. And then a small one on the opposite side faceing the engine. Maybe i dont need to worry about the broken long one then? Can anyone confirm? Thanks,des.

[Jeffer]

The two long ones are not primary needed to run the engine.

Cheers

[diesel des]

Ok an update. I lifted the head etc last weekend and the engine looks great! I can see the original hone marks etc. The head has no cracks. It had a paper gasket. I fitted the fat layer of a second gasket which added 1mm to the thickness which i worked out to be 0.4:1 lower CR. I also fitted the 7a cams. I still have the timing belt to fit.

This leads to a question. What crank pully etc do i use on a ABY in a UR? Do i need a RR or 3b pully? Anyone have one for sale? What alternator do i use. I have no 20V alts at the moment. thanks,des.

[porkkis]

You can use any old 3 groove 5 cyl pulley. From your old urq engine for example. Also your old alternator + bracket should work just fine.

[kwlw]

You can use any old 3 groove 5 cyl pulley. From your old urq engine for example. Also your old alternator + bracket should work just fine.

Porkkis is right, just remember to put timing belt part from ABY pulley to the ur style one.

Same with alternator, however mine from typ85cq with aircon (a bit different) was not the direct fit. I needed to machine it a bit to fit.

Sau

[diesel des]

Thanks for the help guys! I will take that from the original WR engine.