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Discussion Starter #1 (Edited)
Just so you dont get the impression that I've been laying low lately, I've been working on my best man's 33.

Got a used 16v engine and fully rebuilted it, as the one he had on the car needed a crank and was impossible to find !

Here are some pictures :)
 

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Discussion Starter #3 (Edited)
Taking Block apart - Piston condition

This engine had water in oil - due to a bad head gasket.
As a result to this, pistons were damaged and the oil pump was full of slime ! :vomit:

crank was great though ;)
 

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Discussion Starter #6 (Edited)
block cylinders

Front and rear block plates cleaned and painted

New seals

New stainless steel water seals for block

Polished cylinders - thankfully no damage was made from the bad pistons :thumbs:
 

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Discussion Starter #7 (Edited)
Finished engine

A few pictures skipped at this stages, sorry about that.

New piston rings and big end bearings.
Pistons in
oil pump changed
front and back block plates on - heads on
new water pump, tesnioners and timing belts

dizzy attached - this engine used to be an electronic one - installed a dizzy after changing the oil pump to the long one. Far better than the electronic ignition model ;)

Gearbox washed and cleaned.

All put together
 

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Discussion Starter #9 (Edited)
Other things needed attending

new front brakes pads and also changed the front right hub as the threads were totally gone. The front right wheel was on with only 1 out of 4 wheel bolts tight and secure :eek:

a/c dry filter moved from inside the engine bay to where the servo unit is. Did that to make room for the air flow meter mount and stock air filter box. Used to have pipes connecting to an open type air filter. Air flow meter was just hanging in over the engine.

Pedal unit rusted - leaking master clutch cylinder and master brake cylinder.

New peadal unit, changed servo, changed master clutch and slave cylinders - new slave clutch cylinder.
Surface under, cleaned and painted with blue hammerite paint.

Engine in the car - all connected.

Tons of clips and bits installed that were missing
 

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Discussion Starter #10
Nice work chap:thumbs: wish I could get started on my 1.8 block! Will have to tap KEV up on prices for bearings rings and other bits for my rebuild;)
Think your best man is going to be very happy:thumbs:
He better be ! I'm tired ! :lol:

Started it up, runs like a dream !
Need to fine adjust the throttle bodies as I dont like the way the engine is idling.

Also welded up the exhaust mounts yesterday - they were missing !
Took it for an MOT and passed with flying colours
Also registered the new engine ;)
Loosened up his Konis as they were on full stiff to 1/4 of a round back ! Much better now :thumbs:

Car has now gone to a mates car wash. Will be picking it up later on.

Hopefully I can drive it to Limassol tonight and give it to him, as its his name day today :)
 

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Discussion Starter #12
Thanks Phil :)

I do my best for friends :)

Will be taking more pictures tonight with the finished car.

I've kept a track of expenses, if anyone is interested, this is what the rebuilt cost in Euro:

Engine - 250 euro
Engine gaskets - 65 euro off ebay
Engine paint - Foliatec - 50 euro off ebay
piston rings, big end bearings and thrust bearings - 305 Euro off Turin Imports Australia
Crank seals front and back - 55 euro off Alfa-service - Germany
Water pump, clutch kit, block gaskets - 239 Euro off local dealership
Heads cc'd skimmed valve re profile and pressure check - 250 Euro - machine shop
Block cylinder polish - 40 Euro - machine shop
clutch slave cylinder - 50 euro off ebay
fuel hoses and p/s hose - 20 euro
exhaust mounts - 20 euro
Steering rack joints - 25 euro off local shop
Petal unit and master clutch cylinder - already had it
master brake cylinder - given from a friend
Brake pads - Sent from Andreas in Limassol ( my best man ) as well as engine oil, coolant liquid and ATF oil.
MOT - 35 euro

Roughly about 1500 Euro worth of parts including what Andreas has sent me ! :eek:

So YES ! Rebuilding these engines can be expensive !
 

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Very nice work on the block!:thumbs:

Did you end up putting the old crank back in or find a spare? There was one in ebay recently.

What was the clearance on the main bearings and journals?

I'll be inspecting mine in a couple of weeks. Wait for the pics.
 

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Discussion Starter #16
Its a totally different engine mate, so crank is not the damaged one.
Damaged crank is in his old engine now, which I'm saving for spares ;)
Main bearings are standard ones - not oversized :)
 

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Main bearings are standard ones - not oversized
ok cool.

I have a box of goodies waiting for my rebuild - mains/thrust washers/gudgeon pins/small ends etc.
I will paint the fron and back plates like you have done with the same colour paint. Very nice. I'm keeping my block a silver/aluminium colour and will also paint the gearbox.

I was told that these cranks should NOT be reground as the nitride treatment is very thin.
Always find a good used crank or new one.
 
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