the clips in the clutch kit are if your fitting the clutch through the inspection plate and not removing the box bloody handy imo oviously not if your dropping the engine but being able to do a clutch in like 45 mins is goood lol
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the clips in the clutch kit are if your fitting the clutch through the inspection plate and not removing the box bloody handy imo oviously not if your dropping the engine but being able to do a clutch in like 45 mins is goood lol
Ahh I see,
I'll keep them in a safe place for future need. Can a clutch be changed on an F20 with the box still in? I thought this was only possible with the small block engines.
tbh thinkiing about im pretty sure your tight so god knows why there suppliying you with it lol cause you havent got the big inspection plate or the removable shaft unless you bother to use them to line the clutch up lol one of lifes little mysterys hahaha
Meh.. either way I'll put them aside.
It can be changed with the box in as long as you are running the flat flywheel and not the pot one.Quote:
Originally Posted by Nova_Tek
I'll be running the flat fly :)
Dude, it's really soft ally, you can cut it off with 1min with a hacksaw!Quote:
Originally Posted by Spudly
Power tools are more fun :)
True, but if you cant get too it and a small girl could cut it off by hand...
Yes but girls use hacksaws and men use powertools!!! lol lolQuote:
Originally Posted by Benn
^ lol
Power tools mean you do less work ;)
Continuing on from yesterday...
I had a spare few hours in the early afternoon to try get some stuff done.
First up was cutting off the lug on the gearbox. Whipped out the diamond metal cutting wheel (This bad boy again... not made from diamond lol )
https://images2.imgbox.com/6c/9a/uyGY5Ijt_o.jpg
http://img269.imageshack.us/img269/7640/1003183z.jpg
A few minutes and 25,000 rpm later it was off :)
https://images2.imgbox.com/ad/f9/xMx41ose_o.jpg
http://img52.imageshack.us/img52/4129/1003184a.jpg
I took it right back as far as I could. I then gave it a quick rub down and coated that bit in Hammerite too.
I then took the bolt which I was going to use as a sump bolt for the diff pan and chopped that to size. Great thing is that the hex head is 19mm just like the oil sump bolt so one socket for both.
http://img801.imageshack.us/img801/2183/1003185l.jpg
I then wanted to give the diff plate some oil resistant lacquer to protect the paint as I had left it as a matt black.
https://images2.imgbox.com/72/dc/cWdeXEbb_o.jpg
http://img607.imageshack.us/img607/1894/1003188w.jpg
All that is left is the gearbox seals and I think I'll need to organise driving down to the other side of the Thames to hand over the LET to be put together.
:thumb:
UPDATE
After working 9 days straight, today was a day off... Kinda woke up a bit late lol
I got these in the post
Fly wheel cover
https://images2.imgbox.com/95/d8/R4GkI7IK_o.jpg
http://img208.imageshack.us/img208/757/1003193a.jpg
Long wiper linkage as mine was too worn to hold on to the ball joint
https://images2.imgbox.com/f9/8a/UTW009f2_o.jpg
http://img705.imageshack.us/img705/3131/1003192r.jpg
Then made a trip to my second home.... Vauxhall!
Got what I've been looking for... oil filter pick up
https://images2.imgbox.com/50/5e/U5dWMT9n_o.jpg
http://img535.imageshack.us/img535/4686/1003191z.jpg
Then went over to Halfords to get some washers with the trade card.
http://img641.imageshack.us/img641/7209/1003190q.jpg
https://images2.imgbox.com/e9/d2/LPhQTAdU_o.jpg
Smaller pack was £3.99 and the large washer pack was £9.99. Got the lot for £7 on trade :)
Gave the wiper linkage a coat of black to stop it from rusting and for it to make the rest of the linkage that I sprayed up before. Just need the weather to ease up so I can sort stuff out.
https://images2.imgbox.com/81/bc/7B5Myodb_o.jpg
Wiper bit wont rust, but good work.
Cheers Benn, I know they don't rust as such but they still go manky and dirty which is why I painted it.
Here it is anyway all dry
http://img855.imageshack.us/img855/2655/1003200m.jpg
Got these in the post also... some misc M6 & M7 hex bolts
https://images2.imgbox.com/c8/73/YuZmwnry_o.jpg
http://img27.imageshack.us/img27/7453/1003199q.jpg
Sun came out so I jumped into the garage to get the gearbox gaskets on... started off with the cluster and forgot to take a picture. I then did the end plate gasket and made sure I took a picture :)
https://images2.imgbox.com/79/eb/0WsaB2RR_o.jpg
http://img826.imageshack.us/img826/7738/1003194o.jpg
I then moved on to the selector housing gasket and forgot to take a picture again, typically remembering that I didn't as I was doing up the bolts lol
Wanted them to dry completely before I turned it upside down to do the diff cover... so I moved on to the seals. Thought I was on to a winner when trying to remove the o-ring seal but I only took of the metal ring :(
https://images2.imgbox.com/54/7d/D9bzslai_o.jpg
http://img19.imageshack.us/img19/7987/1003197k.jpg
Then came out the hammer. I tried to prise it out with the hammers forks underneath the seal with another hammer persuading it off. I felt it started to give but it didn't budge hmm.....
http://img833.imageshack.us/img833/4982/1003195m.jpg
One bent hammer :(
https://images2.imgbox.com/31/9b/QsaU3dYM_o.jpg
And one half chewed up seal
http://img607.imageshack.us/img607/6351/1003198r.jpg
https://images2.imgbox.com/d8/fc/yn486ULJ_o.jpg
Then started the thunder and hail. Off I went in.
Is there not a better way to take these out apart from butchering them?
I also realised that the oil filter pick up screw I got yesterday is not the right one... it is the correct one for the LET but won't work with my sandwich plate. It's too short for it to actually fix the sandwich plate to the pump and give enough thread for the filter to screw on to, but too long to use the sandwich plate's own extender pick up thread. I should've got a non-oil cooler pick up screw like off a SEH or XEV etc.
Shall have to order one.
I remove the shaft seals from behind with a punch and they come out fairly easily, although not overly useful unless you're willing to take them out/drop the diff out.
There's a spring behind the rubber part so make sure that hasn't fallen off into the gearbox casing during your butchering.
I had my mate change the diff recently, totally forgot to tell him to get the seals off ( I was at work so wasn't involved with it). I know that these seals no matter where they are, pretty much need to get ripped out for them to come off but this one didn't shift with all that force. May need to make up some sort of pulling device.
UPDATE
Another couple hours of free time today so I decided to have another go at removing the seals.
Raided the garage to see what I could find to help me... then found my trusty crow bar
Just managed to fit it into the hole and gave it a few whacks with the hammer (a different one ). Then removed the crow bar and put the hammer underneath the seal. A couple jerks and off it popped
https://images2.imgbox.com/b0/3e/nzxJaXvw_o.jpg
Cleaned up the area
https://images2.imgbox.com/28/b6/BBIAQMVz_o.jpg
and gave the bearings a good covering/packing of LM bearing grease.
The seals I took off had a bit of gasket type sealant around it so I did the same with the new ones. Took out my largest socket to 'persuade' the seal in and ended up butchering it
Got the other one out and tried to use a different tactic... nope still messed it up. Need a much bigger socket in order to uniformly apply pressure around the outer most edge and not the middle of the metal section of the outer part of the seal (which is what had bent while trying to fit it). So contacted the ebay seller that I got the seals off to see if I can buy some more.
I then removed the diff oil filler plug to clean it up and found this inside it
https://images2.imgbox.com/c9/28/WxdmdtNW_o.jpg
Tis a magnet! IIRC this isn't standard issue right? Either way I kept it and gave it a good clean. So I've gone and delayed myself due to butchering the new seals so will be getting that sorted in the week when the new ones arrive.
On the look out for a quality scuttle cover as I hate the standard noisy, thin, cheap cover that covers the heater blower motor.
That's the level plug, filler is the breather on the top. Never seen one with a magnet on before.. Wont really do much being up there either... Seals are a night mare too fit. I use a bit of 2.5" exhaust tubing to tap them home.
Make a scuttle cover, they are easy as.
I use a 30something mm socket to fit the seals,acting as a drift.
I also fill mine via the selector housing hole,much easier imo.
See all the mechanics that I've seen fill a Vauxhall diff with oil is via this plug as when it overflows it means it's got the correct 1.8/1.9 litres of oil. Apparently the selector housing hole it just a breather. either way works so don't really bother me.
May be something I will just make when everything is sorted as it's not urgent.
I had a 32mm socket but that only covered the inner metal section of the seal and bashing it bent that section. May have to find a metal pipe like you said Benn.
UPDATE
Nothing major but I've sorted out the sandwich plate. The oil pick up threaded tube I got was the wrong type (that was to use with the standard sandwich plate). So on the phone to Autovaux yesterday ordering a standard non-oil cooler threaded tube and it arrived today... swift!
https://images2.imgbox.com/dd/7b/X817y7Ph_o.jpg
http://img109.imageshack.us/img109/7895/1003205f.jpg
And all the relevant bits now fitted to the oil pump... yay!
http://img13.imageshack.us/img13/3302/1003206m.jpg
That is all for now...
UPDATE
Busy week at work... keep forgetting to arrange a day to drop the engine off to my mechanic mate :( and now I have man flu... feel totally bushed!
I got this today dropped off by the courier guy
http://img262.imageshack.us/img262/6024/1003207.jpg
https://images2.imgbox.com/b6/ff/yFt2bWyT_o.jpg
Millers Fully synthetic 10w-40 for the LET. I got it together with an aluminium portable Toshiba 500GB hard drive for £11 lol (thank you Amazon e-voucher!)
Still waiting for the oil seals to arrive for the gearbox... at least the weather is starting to get better (now that I'm ill :( )
My gearbox plug is like that too. When I first removed it there was some pickup on it :)
Yeah that magnet in the level plug is normal. Being at the top of the fluid level I guess it picks up anything metal that floats? Filling via the breather hole and checking the level with that plug is easy really.
Cool... infact if you remove the breather nipple from the selector housing you can fill the box up quicker ;)
UPDATE
It's been a while so I thought I'd just update everyone on what's happening right now.
I've slowly been doing the usual parts look out for little bits and pieces I need for the build. Being married for 4 years, priorities change to which they have. Decided that buying a house is one of the most important things currently... so I've been saving as much of my wage up as possible to be able to afford a down payment for my first place. This has no doubt slowed the project down.
Work has been full on, which I actually don't mind as it gets me closer to affording a place and in this day and age more work isn't a bad thing. I did actually manage to have a few days off in a row back in July, which I arranged to go down to south London to drop the engine off to a good mate to get it built (like I mentioned in the last few updates). I was certainly feeling good and excited. Got the LET in bits into my brothers Cav and headed down. Took 50 mins to get there lol
Met up with the fella and he come to sort out some details with what was what etc. He took one look and the block and started shaking his head. He said that the bores had uneven wear and would be better off getting it re-bored or changed. To say I was p*ssed off is an understatement, as I said to the engine shop to let me know what was needed. They said a 'light hone' would be fine. The mechanic did say that he could quite easily rebuild it in its current state and it will run ok for a short while but it would use up oil like nothing else and that I'd be back in not much time after. He felt very uncomfortable knowing the condition and for him to go ahead and rebuild it. He had a couple of his colleagues take a look just to get other opinions.
Decision time:
Change block? or Re-bore?
I've opted to go for re-bore and oversized pistons as I didn't wanna risk buying another block and for that to need honing or boring etc.
40thou rebore (1mm) to increase to 87mm together with 87mm pistons. Looking at pistons, there isn't a substantial difference in price between 86.5mm & 87mm. Boring of the block costs the same for both sizes. Spoke to my other mate who spoke to his mate who owns the engineering shop that did the honing. He had a 'word' with his staff lol and said that he'd deduct the price of the hone off the re-bore - result!
Block is at the shop, which I dropped off before I went on my holiday for it to be checked out. I'm just waiting for the Omega pistons to arrive for me to take it to the shop so they can start on the re-bore. Only problem I have is I need to try return the 86mm Mahle piston rings back to AutoVaux.
That's where the project stands...
UPDATE
A bit more productive this time...
Went and met Steveboyslim in the morning to pick up my new pistons... we're about 5 miles apart so to save time and postage fees a quick trip to him was best.
He's a top bloke with plenty of knowledge and sense... picked up these beauties
https://images2.imgbox.com/46/4e/Fb0JVCg4_o.jpg
https://images2.imgbox.com/16/af/KXADkTkN_o.jpg
http://imageshack.us/a/img207/1127/imag0621i.jpg
https://images2.imgbox.com/94/3f/BbgOhbYT_o.jpg
http://imageshack.us/a/img850/8783/imag0620n.jpg
Pure engineering Pr0n- 4 new Omega pistons with rings, pins and clips.
Then went and had a spot of breakfast and dropped the pistons to the engine shop to measure up and bore to the exact size.
Should get the block back in the next few days...
Does Steve look like his brother fatboyslim
lol not quite
Looks like chips dad...
The diff plate is a nice little touch
Cheers dude... should be very handy and a practical solution :)
Any updates??
UPDATE
Just for the record I got my block back a few weeks ago, all re-bored to 87mm. Have tried to get the engine down to my mates shop but he's been away or I've been working a full week
Have had trouble finding enough free worth while time to actually get any real progress done
Now that I had bought myself an impact gun, I could finally attack the calipers and change the front brakes... unfortunately it wasn't as easy as that! Even with the gun at full trigger it wouldn't budge. Tried WD40 but still, then tried a wrench and a big ol' mallet. Still seemed impossible. A trip to Halfords found a can of 'Shock & Unlock' - a penetrating fluid which shock cools the nut/bolt and allows it to free off. This time I made myself a make-shift breaker bar from different tools and hollow tubes so I could angle away from the arch/wing.
After much force I heard a snap! Still very difficult to undo but that's where the impact wrench did the rest... Finally the caliper was off!!!
Next problem was the fact that the little brake disc retaining screw was bent and was a nightmare in itself to take off. Eventually got the disc off, hub looking good and less dirty/rusty that I guess it would be.
https://images2.imgbox.com/14/26/CcqwisEH_o.jpg
Gave the disc shield a good old clean and gave it a coat of stone chip. I had to also bend the shield back a few mm's as the larger discs would obviously foul the shield.
Trial fit the disc to make sure it cleared the shield.
https://images2.imgbox.com/52/9a/vjFLkTCV_o.jpg
Now it was time to fit the calipers
https://images2.imgbox.com/37/fe/9wyj1pPR_o.jpg
Totally easy to fit which was a breath of fresh air as everything else leading up to it was a bit of a pain. Then fitted the brake lines.
During my last visit to Haldfords I got a litre of DOT 5.1 brake fluid for £5.39 (normally £13 - thank you trade card). Bled the front brakes thanks to the £2.99 bleed kit from ebay. There is good pedal feel, nice and firm but I want to bleed the rears as the old fluid is the really old DOT 4 from about 4 years ago. Still need to fit the new Goodridge rear lines but no doubt once fitted and the rears bled there should be an even better feel.
Was my birthday last weekend... got the usual pressies like clothing, money and smellies but also got two things which would be really useful. One of them would be this:
Prosport PSi Boost Gauge
https://images2.imgbox.com/cf/fc/aRmlZePf_o.jpg
https://images2.imgbox.com/82/a5/m3U1NlLS_o.jpg
Comes with everything you need to get them to work, they can be daisy chained so you only need to wire one in and the rest will run off the other. This model is setup by a touch sensitive control switch, multiple colour display and have warning beep or peak light which can be setup to desired value.
Here's how it should look when on as when they are off the dial face is almost blacked out
https://images-na.ssl-images-amazon....ZL._SY355_.jpg
The other gift on it's way - it's a vernier pulley to help dial in the XE inlet cam when it is fitted.
I'm trying my best to get this project finished but time is definitely of a finite abundance at the moment.
Ooo the gauge is very nice.
They are Benn ;) This one, which is top of the range is only £60
UPDATE
Been real busy... unfortunately not on the Nova :(
Busy with work as usual taking on more responsibility and work as my manager was away for a whole month thus me having to take care of as much as I could. Worked solid 6 days a week, but not going to complain though as it's miles better than being unemployed so I can only be grateful. This does mean that the Nova is still on hold, and to be honest I can't see anything further happening until things go back to 'normal' after christmas & new year.
I have got a couple more new bits to add to it, but just to give you an idea of how much time I don't have... I got these bits almost 3 weeks ago. Compared to how quickly I used to update my thread before this is dire!
Anyway got a friend for the boost gauge:
https://images2.imgbox.com/ab/ba/pjplxg2V_o.jpg
http://img14.imageshack.us/img14/573/1003211e.jpg
And got these as well:
https://images2.imgbox.com/da/57/NydPEuv0_o.jpg
http://img819.imageshack.us/img819/5344/1003210t.jpg
Brake disc securing screw. Only needed one but Vauxhall only sold them in 25's lol
Hoping to get more bits 'n bobs over xmas/new year to add.
Really need to get this project in to gear (pardon the punn) after the new year... I am beating myself up for the big project slow down but such is life.
I got one of them pillar pods, but ordered the wrong one. If you still want one i have a mk1 fit one here.
Is it black in finish? 2 pods? How much on trade? lol