Turbo Technics Engine Rebuild

[Guest rick03054]

This is probably going to end up a huge rambling post because I just keep jumping back and forward about what to do here, so bear with me. I've added a summary at the end. I don't have anyone knowledgeable I can speak to in the pub about this so you lot are now my cyber-drinking buddies, I'll get the virtual beers in while you listen to my rant....

 

I've decided to strip down and rebuild my turbo technics engine and probably put it in my laser for the spring time. Right now it's in bits, the easy part is done....

 

Since I've never rebuilt an engine before I'm going to get everything professionally checked and get them to hone the liners, replace any valve guides that need done, all that kind of stuff that I can't do at home. I want to do as much myself as possible.

 

My first 2 dilemmas are what to actually put to the engineers to be checked, I'm not sure on whether to rebuild it to standard (TT) spec or whether to do a couple of mods while it's apart, nothing spectacular, just a little something extra. I also don't want a couple of mods to turn into a hugely expensive monster of an engine! you know how easy it is to get carried away

 

So my plans were:

 

1) XU10J2 head with XU9 cam, this appears to be a relatively cheap mod which should work well on the TT, lowers compression slightly and flows better. I've read on the forum that you really need to get the valve seats done to get the most out of it (3 angle I assume?) is that expensive?

 

2) Mi16 crank, which is why I was asking here whether the XUD9 cranks are the same, the consensus on this was that they don't have the chamfer's on the counterweights to clear the oil spray bars but can be swapped without problems. So I could just get an XUD one from a scrappy to save some cash there.

 

The other reason for the crank is the state of the big end bearings, I stripped a 1.6 engine so that I wasn't doing it for the first time on the important one, that was a damn good idea I was far more confident the second time around. The bearings in the 1.6 were nice and smooth and newish looking, the ones from the TT were pitted and scratched and the bit in the middle of one seems like it had actually been scraped across onto the other shell!

 

Here's some links to pics of the bearings, excuse the quality of them I just couldn't get any decent ones without loads of glare or just the background being in focus .

 

Middle bit smeared up and corners worn away.

Scratched and pitted

Ouch is all I can say about this one

 

With that much damage it seems likely to me that the crank will need a regrind anyway, so why not upgrade it.

 

I have an Mi16 flywheel, sometime in the distant future I'll go for an aftermarket ecu. I had thought about using a 605/xm turbo ecu I have and getting it remapped but that'll probably end up costing as much as an aftermarket job. The option is still there if it's worth it for the bigger clutch. It did have a paddle clutch but theres no material left on it.

 

Then there's the issue of whether it's worth getting it balanced, I just want as nice running an engine as I can get for not too much cost and hassle. I don't think I'll be doing this but I'm completely open to any suggestions anyone has.

 

I don't have a set power I'm after and I don't have a set completion date. I'm happy to wait and save up a bit for the little extras that will improve the engine. I just can't decide what's worth it.

 

Thanks for reading, let me know if anyone has any suggestions .

 

EDIT: A summary would probably be a good idea.

 

Basically I want to know the value of these mods:

 

1) XU10J2 head possibility of 3 angle seats

2) XUD9 crank

3) Mi16 flywheel + clutch

4) balancing

5) Any other suggestions

 

And also any comments on the bearings would be appretiated.

Edited January 13, 2007 by rick03054

[saveloy 8]

I have an Mi16 crank. It is a very worthwhile upgrade. If you are going to lengths and are not going to lighten/balance everything, then you aren't doing things seriously.

Renew all the bearings, pointless not to.

An Mi flywheel, again lightened/balanced, is a good idea. Future proof the conversion and it allows the use of a larger 215mm clutch unit. Use an organic uprated, not a paddle.

Using the XU10 head can be troublesome. Only in the sense that if you use an XU9 gasket it will fail. Since it will protrude into the chamber and open to the elements. Get a gasket made specifically, or stick with the XU9 head. Be sure to check the entire head for tolerances and wear and give it a light skim.

Flowing the head lightly works a treat. As does removing any lips, or raised edges in the exhaust manifold and downpipe.

[Guest rick03054]

Sounds like a plan to me

 

Bearings etc. are a given, along with waterpump, rings, stem seals....

 

If the balancing is important I'll write it into the equation, I wasn't sure since not high revs. And I'll look into getting an Mi16/XUD9 crank now. As I said I want a descent engine with as little hassle as possible I think I'll sack the XU10 head idea, although apparently some people have run XU9 gaskets without problems, nickpug309tt says he has in the thread I linked to above anyway. However I think a flowed head may be out of my budget at the moment.

 

What bearings do you use with the Mi crank? This is where I'm a bit wary too, I know with the Mi crank in an S16 block you need diesel bearings, what happens in this case?

[Guest rick03054]

Also, can any engine reconditioner balance parts or is that a specialist thing?

[Kev-G 1]

What about an Mi block to give you oil spray's to cool the pistons?

 

I've also got a 1.9D crank available and management from a 2.0T.

 

PM me if interested - Nr. Dunfermline.

[James_m 0]

I would'nt bother with balancing, as you've already said, things can quickly get very expensive with engines....

[TEKNOPUG 3]

You need to go to a specialist to get the engine dynamically balanced (all parts balanced together at once - crank, flywheel, clutch). Bit overkill on a turbo engine though as you won't be running high revs.

[saveloy 8]

I believe I'm using std 8 valve bearings.

As I said, if you are going to do things properly, balancing is more of a necessity than a luxury.

It will reap benefits in throttle response, smoothness and a more eager swing to the red line.

[Guest rick03054]

Thanks for the replies everybody, it's all much appreciated.

 

You need to go to a specialist to get the engine dynamically balanced (all parts balanced together at once - crank, flywheel, clutch). Bit overkill on a turbo engine though as you won't be running high revs.

That's what I thought, the company I've approached may not have the capabilities. I've still to ask them but I want a solid plan before I phone them...

 

I believe I'm using std 8 valve bearings.

I had hoped that was the case, similar components etc... however I've seen T16 bearings on the hiflow website, but I've heard softer/lesser model bearings are better (for the crank anyway(softer))

 

As I said, if you are going to do things properly, balancing is more of a necessity than a luxury.

It will reap benefits in throttle response, smoothness and a more eager swing to the red line.

 

Oh crap, a mixed response then, or is it a case of Saveloy you have a pretty high end engine, where balancing is an acceptible expense? (~£200?) where as a budget engine could go without with little penalty, being a turbo which shouldn't really need to go to the redline very often? I realise balancing will always be an advantage, I'm just wondering whether I NEED to/should do it.