Project: Xu12J4

[jonathan_steenbergen 5]

Hello,

 

After long thinking, calculating and even more thinking ...
I started with the build of a 2.2 XU.

It started with being able to buy a brand new crankshaft of a XU11TD.
Then I bought a complete S16 engine.

And then it started...

 

The plan is as follows:
-88mm XU10J4 engine

-XU11TD crankshaft
-XU10J4RS conrods (158mm)
-Honda forced pistons
-Cylinder head with little modified combustion chamber
-1mm oversized inlet valves (modified TU valves)

-Catcams 4912527

-XU10J4RS inlet manifloid (later maybe trottle bodys)

-Vems aftermarket ECU from DP-Engineering

 

I'll post pictures later of all the parts i already have! and what I've been doing the last months!

 

 

Greets

 

 

 

 

 

 

 

 

 

 

[jonathan_steenbergen 5]

Crank:

http://img802.imageshack.us/img802/7072/wp001058.jpg

 

http://img22.imageshack.us/img22/7514/wp001056.jpg

 

Engine:

http://img62.imageshack.us/img62/7872/wp001079.jpg

 

More later!

[jonathan_steenbergen 5]

gti6 158mm rods:

http://img138.imageshack.us/img138/6657/wp001230.jpg

 

engine:

http://img580.imageshack.us/img580/7536/wp001217.jpg

 

http://img811.imageshack.us/img811/2374/wp001218.jpg

 

Old and new crankshaft:

http://img546.imageshack.us/img546/7709/wp20130227007.jpg

 

Testfit with s16 rods and pistons to see if iets real 92mm stroke :-):

http://img824.imageshack.us/img824/8611/wp20130227010.jpg

 

http://img189.imageshack.us/img189/5339/wp20130227025.jpg

 

http://img96.imageshack.us/img96/8817/wp20130227028.jpg

 

bye

[welshpug 1,666]

this pic highlights why custom rods should be used, see the gap at the side of the conrod!

 

[B1ack_Mi16 67]

Yes. XU11D crank has 26mm wide rod journals, same as XU10J4TE engine has orginally. Most other XU engine has 24mm wide ones.

Custom conrods are preferred as now you need to piston locate the rods as on the 1.9 Mi16 engine.

 

The honda pistons (if same type as I got for my 2.2 T16 apart from the dish) won't be tight enough to allow for piston locating the rods anyways, they are also conical in the wrist pin area so would need machining flat in case of piston locating them.

[B1ack_Mi16 67]

Btw. it you decide to get new rods I can give you the prod. number on my Pauters.

With slight modifications to length and small end thickness on those I think you will get the right ones.

[jonathan_steenbergen 5]

Thanks for the comments!

The idea is to get the con rod in the right place on the piston pin if possible and safe, maybe a little machining and filling up te space.

It's wait and see what the space is in the honda pistons,

 

The project is not finished yet, and am still thinking and measuring!

But ideas and tips are always welcome!

[pip470 61]

I also have made spacers either side of where the conrod sits in the piston and slides over the gudgen pin making it piston guided. Yet to test the engine but its quite similar to yours. I have forged pistons and rods and going for a compression ratio of 13to1. Good look with your project.

[pip470 61]

Heres the pics.

[jonathan_steenbergen 5]

Thanks, nice!

 

Con rod in big end 24 or 26 wide?

[B1ack_Mi16 67]

Probably 24mm, if not no reason to use the washers to centralize rods.

[jonathan_steenbergen 5]

Long time but still busy on the engine some times!

The more time, the better the ideas get. That is the positive thing .

 

Also bought a 309GTI16 racer, thats is ready for some more horsepowers, so i can keep the other one original.

 

Now working on the cilinderhead,

He has already been machined near the valves so there is more space for the air to come in 

Now I have to make a nice whole by hand and when this is done i know how many cc they have become and then I can order the pistons.

 

Regards

 

Edited March 25, 2019 by jonathan_steenbergen

[jonathan_steenbergen 5]

On 4/15/2013 at 6:17 PM, jonathan_steenbergen said:

Hello,

 

After long thinking, calculating and even more thinking ...
I started with the build of a 2.2 XU.

It started with being able to buy a brand new crankshaft of a XU11TD.
Then I bought a complete S16 engine.

And then it started...

 

The plan is as follows:
-88mm XU10J4 engine

-XU11TD crankshaft
-XU10J4RS conrods (158mm)
-Honda forced pistons
-Cylinder head with little modified combustion chamber
-1mm oversized inlet valves (modified TU valves)

-Catcams 4912527

-XU10J4RS inlet manifloid (later maybe trottle bodys)

-Vems aftermarket ECU from DP-Engineering

 

I'll post pictures later of all the parts i already have! and what I've been doing the last months!

 

 

Greets

 

 

 

 

 

 

 

 

 

 

I see that the specs changed al little 

 

-88mm XU10J4

-New XU11TD crankshaft

-XU10J4RS conrods (158mm)

-Honda forced H22 pistons

-XU10J4 Cilinderhead (without the unnecessary oil supply around the lifters)

-Modified combustion chamber because of the bigger bore

-Mech lifters because of the much bigger cams.

-Bigger cams

-Oversized lighter valves (modified TU valves)

-48mm Jenveys

-Aftermarket ECU

-And a lot of other small modifications

 

[jonathan_steenbergen 5]

Long time ago, 10 years ;-). Still working on it.. busy, house, shed, business but perfectionated it in the last years. Maybe some pics soon.

[DrSarty 90 1 Cars]

I always love variety & projects. People trying new combinations is great.

 

My only question (concern) with the above build list, is using the GTI6 rods.

 

I may be wrong & hope to be proved wrong again here, but I've heard of people saying that the GTI6 has "chocolate pistons". Is that just the pistons themselves or are GTI6 rods OK?

 

I stuck with a forged but standard crank, but thought it safer to invest in custom rods to go with my fudged pistons. Is that with considering for you, or are GTI6 rods airtight?

[petert 601]

Great project! Using stock rods is a false economy. By the time you've closed and honed the rods, then fitted new rod bolts, you're well on the way to a new set of rods.

 

Additionally, GTi6 rods have a pressed pin. Unless you use an Ø18mm pin, there's insufficient material to bush them.

 

Edited December 5, 2023 by petert

[jonathan_steenbergen 5]

Needed the gti6 rods for the 138mm lenght, so bought the ori ones in the beginning but forged are already in stock ;-). 

PEC made for Wossner turbo conversation piston Little to much space on piston pen with the 88mm H22 Wiseco pistons.. so gonne make the clearance right with bronz bushes.

 

Hope to have the head ready this winter. Have matched the ports with the jenvey inlet an the combustion rooms are few cc bigger to math the bore an comp ratio. Chosen the roght cams and almost everything from catcams for the head.

 

In the years you get wizer ;-).

 

Also need to shim the rod in the piston because of the wide space there. Like as few mm's now. Dont want then to run in to the radius of the crank bearing space.

 

Still same drive on the project as a long time ago but been reshaping a house, building a shed, garden an built up my company futher so bit by bit!

Edited December 8, 2023 by jonathan_steenbergen

[jonathan_steenbergen 5]

Head almost ready. Ordered lashcaps for setting clearance of the mechanic lifters. Mounted crank for shimming the pistons.

 

Pics :⁠-⁠)

 

 

[petert 601]

I made eight, identical test lash caps from aluminium for shimming those lifters. You never get them right the first time.

[jonathan_steenbergen 5]

On 2/3/2024 at 2:03 AM, petert said:

I made eight, identical test lash caps from aluminium for shimming those lifters. You never get them right the first time.

Ah oke. Didnt expect to have everything right the first time ;⁠-⁠)

 

But bottom finished, head ready for now.

 

Hope to have the blue 309 out of the shet soon en let the engine bay blasting and painted.

 

Meanwhile finding time to make the engine complete. 

Ecu will be KMS, also will be going there when finished for the making it run.

Edited April 13, 2024 by jonathan_steenbergen

[Richie-Van-GTi 74 2 Cars]

Bit of a long shot, do you still have the S16 rods and pistons?

[wicked 105 3 Cars]

On 4/13/2024 at 11:58 PM, jonathan_steenbergen said:

 

Hope to have the blue 309 out of the shet soon en let the engine bay blasting and painted.

 

Good to see it being restored to former glory! 

Keep up the good work... 

/Rolf

 

[wicked 105 3 Cars]

On 4/14/2024 at 4:26 PM, Richie-Van-GTi said:

Bit of a long shot, do you still have the S16 rods and pistons?

Shipping parts from the Netherlands to Uk can be a tedious job to get the paperwork right..

Can't imagine that there are no pistons to be found in UK? 

[Richie-Van-GTi 74 2 Cars]

2 hours ago, wicked said:

Shipping parts from the Netherlands to Uk can be a tedious job to get the paperwork right..

Can't imagine that there are no pistons to be found in UK? 

Been looking for a while and none are forthcoming. Would happily pop over to the Netherlands for the right deal, can make a weekend of it

[petert 601]

I thought I'd written this. Maybe I just imagined it. ie

 

You can't finalise the valve clearances until the head is torqued down. Even the belt tension changes the #4 clearances. Push down the pulleys to simulate tension whilst checking clearances.