Project Q-Felicia

TeflonTom · 23-07-2007, 12:12

spent a bit of time assembling the piston/rod assemblies today.......

then i put the new piston rings on to the pistons with a specail tool for spreading the rings without breaking them

another top tip.. put the shell bearings into the conrod before you put the rod/piston in the cylinder block

using another special tool for compressing the piston rings whilst insertin them into the bores

TeflonTom · 23-07-2007, 12:14

my advice to anybody is to insert all the pistons at the same time to save keeping turning the engine over... i allways put them all in so they are all level with the deck like this.

TeflonTom · 23-07-2007, 12:18

after they are all in thier respecting bores, turn the engine upside down and fit the cap(also with a new bearing shell) onto the rod and tighten it down to the specified torque setting...

you may notice that i have temporarily re-used the old conrod/big end bolts, you should renew these every time they are undone because the tightening process stretches them, i've only put these back in loosely whilst i'm waiting for my new ones to arrive.

TeflonTom · 23-07-2007, 16:13

decided to fit the oil pump on today as well...

i had to find a suitable oil seal for it because the one supplied in the conversion gasket set was the wrong size... went to Brt bearings in portsmouth and it was like £3 or something.

next i i fitted the crankshaft sprocket

lord knows how they tighten these up to the right torque setting when the engine is still in the car!!! anywho, take it from me, it's f-ing tight.. 90nm then 90degrees....

in case you were wondering.. the big round hole to the bottom right of the oil pump is where the water pump goes(remember the engine is upside down in this picture!)

TeflonTom · 23-07-2007, 22:10

right.... i'm going shopping tomorrow

well.... scrapyard shopping anyway

i need
1) distributor from 6n polo
2) thermostat housing
3) 2.5 bar fuel pressure regulator
4) might see if i can get some polo rear stub axles/calipers for the rear disc conversion too
5) also on the lookout for a pair of front hubs so i can start looking at the big brake conversion.

i've ordered a piper camshaft as well, so that should be here in a few days hopefully

TeflonTom · 24-07-2007, 15:32

guess what.... they're here! but....... i've just had a quick look at them and one of the spindles is jammed so i'm gonna have to strip it down to find out what's wrong with it..... an no.... i'm not sending them back

TeflonTom · 24-07-2007, 15:51

problem solved.. a tiny burr on in the throttle bore was stopping it from opening..

WoodieGuthrie · 24-07-2007, 20:51

woohoo! you have throttle bodies

and an engine looking a lot healthier

TeflonTom · 24-07-2007, 21:06

head goes on tomorrow hopefully

TeflonTom · 25-07-2007, 17:40

fitted the oil pick up pipe

then the sump, unfortunately the windage tray i bought doesn't fit this engine

so it aint going in

TeflonTom · 25-07-2007, 17:41

after fitting the sump i quickly popped the head on and torqued it all down to the correct tension, 60nm +90 degrees +90 degrees

view from other side of engine

richardsfavorit · 25-07-2007, 18:35

Looks great - keep up the good work

pinkskud · 25-07-2007, 20:03

looking good, looking good.

WoodieGuthrie · 25-07-2007, 20:22

bloody hell!

I'm hoping to pull the lump out my touring this weekend and tidy her up.

not opening her though-if it aint broke, dont fix it!

very impressed with the workmanship Tom

vrswhite · 25-07-2007, 21:22

wow i have just read all that link took me an hour.

propper good dude

TeflonTom · 26-07-2007, 12:47

next job is to fit the coolant transfer pipe and thermostat housing

TeflonTom · 26-07-2007, 12:53

next i fitted the new water pump... part of the timing belt cover is also retained by the same bolts that hold on the pump so this goes on at the same time

TeflonTom · 26-07-2007, 12:55

next i fitted some new manifold studs. then the exhaust manifold goes on...

TeflonTom · 26-07-2007, 15:37

had some more goodies turn up today.

this kit is quite basic, it just contains the timing belt and tensioner

TeflonTom · 26-07-2007, 16:00

next spark plugs go in!

then fuel rail and injectors
then the throttle bodies

here's a different view of the bodies, you can see that they have been drilled for fuel injectors then plugged, this is handy for me if i ever decide to fit another set of injectors

TeflonTom · 26-07-2007, 16:03

it's all coming together finally, starting to tie up all the loose ends now... i've even found a suitable fuel pressure regulator, came out of a mondeo with a 2.0 zetec engine..

camshaft not arrived yet but should be here tomorrow

WoodieGuthrie · 26-07-2007, 16:52

WOW!

inspirational.-excellent work, I'm bloody jealous!

TeflonTom · 27-07-2007, 08:52

right then folks..... i'm off to skospares in poole......

update later

TeflonTom · 27-07-2007, 17:34

picked up a few bits and pieces today..

got a pair of front hubs, going to strip them down and measure them up ready so i can make up some brackets for the big disc conversion.

here is the right hand engine mounting bracket

the one on the right is the one for the 6n polo, the one on the left is for the felicia, you can see the similarities bewteen them, they both use the same mounting holes in the engine block

TeflonTom · 27-07-2007, 17:35

here is that bracket fitted to the engine block

23-07-2007, 12:12	#226
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! spent a bit of time assembling the piston/rod assemblies today....... then i put the new piston rings on to the pistons with a specail tool for spreading the rings without breaking them another top tip.. put the shell bearings into the conrod before you put the rod/piston in the cylinder block using another special tool for compressing the piston rings whilst insertin them into the bores

23-07-2007, 12:14	#227
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! my advice to anybody is to insert all the pistons at the same time to save keeping turning the engine over... i allways put them all in so they are all level with the deck like this.

23-07-2007, 12:18	#228
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! after they are all in thier respecting bores, turn the engine upside down and fit the cap(also with a new bearing shell) onto the rod and tighten it down to the specified torque setting... you may notice that i have temporarily re-used the old conrod/big end bolts, you should renew these every time they are undone because the tightening process stretches them, i've only put these back in loosely whilst i'm waiting for my new ones to arrive.

23-07-2007, 16:13	#229
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! decided to fit the oil pump on today as well... i had to find a suitable oil seal for it because the one supplied in the conversion gasket set was the wrong size... went to Brt bearings in portsmouth and it was like £3 or something. next i i fitted the crankshaft sprocket lord knows how they tighten these up to the right torque setting when the engine is still in the car!!! anywho, take it from me, it's f-ing tight.. 90nm then 90degrees.... in case you were wondering.. the big round hole to the bottom right of the oil pump is where the water pump goes(remember the engine is upside down in this picture!)

23-07-2007, 22:10	#230
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! right.... i'm going shopping tomorrow well.... scrapyard shopping anyway i need 1) distributor from 6n polo 2) thermostat housing 3) 2.5 bar fuel pressure regulator 4) might see if i can get some polo rear stub axles/calipers for the rear disc conversion too 5) also on the lookout for a pair of front hubs so i can start looking at the big brake conversion. i've ordered a piper camshaft as well, so that should be here in a few days hopefully

24-07-2007, 15:32	#231
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! guess what.... they're here! but....... i've just had a quick look at them and one of the spindles is jammed so i'm gonna have to strip it down to find out what's wrong with it..... an no.... i'm not sending them back

24-07-2007, 15:51	#232
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! problem solved.. a tiny burr on in the throttle bore was stopping it from opening..

24-07-2007, 20:51	#233
WoodieGuthrie Briskodian Join Date: Jul 2006 Location: Glasgow Posts: 813 Members Car: Totally Stock:-) Thanks: 6 Thanked 29 Times in 23 Posts	Re: OMG! It Begins! woohoo! you have throttle bodies and an engine looking a lot healthier

24-07-2007, 21:06	#234
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! head goes on tomorrow hopefully

25-07-2007, 17:40	#235
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! fitted the oil pick up pipe then the sump, unfortunately the windage tray i bought doesn't fit this engine so it aint going in

25-07-2007, 17:41	#236
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! after fitting the sump i quickly popped the head on and torqued it all down to the correct tension, 60nm +90 degrees +90 degrees view from other side of engine

25-07-2007, 18:35	#237
richardsfavorit Briskodian Join Date: Jan 2007 Location: Newtown Wales Posts: 532 Members Car: Skoda Octavia 1.6 Ambiente Thanks: 37 Thanked 34 Times in 34 Posts	Re: OMG! It Begins! Looks great - keep up the good work

25-07-2007, 20:03	#238
pinkskud not a bird!!! Join Date: Sep 2006 Location: pixi said not to fill my box Posts: 2,158 Members Car: 1.6l felicia 1998 Thanks: 1 Thanked 78 Times in 74 Posts	Re: OMG! It Begins! looking good, looking good.

25-07-2007, 20:22	#239
WoodieGuthrie Briskodian Join Date: Jul 2006 Location: Glasgow Posts: 813 Members Car: Totally Stock:-) Thanks: 6 Thanked 29 Times in 23 Posts	Re: OMG! It Begins! bloody hell! I'm hoping to pull the lump out my touring this weekend and tidy her up. not opening her though-if it aint broke, dont fix it! very impressed with the workmanship Tom

25-07-2007, 21:22	#240
vrswhite Briskodian Join Date: Sep 2006 Location: doncaster - yorkshire Posts: 694 Members Car: white octavia vrs 02 plate Thanks: 4 Thanked 17 Times in 17 Posts	Re: OMG! It Begins! wow i have just read all that link took me an hour. propper good dude

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26-07-2007, 12:47	#241
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! next job is to fit the coolant transfer pipe and thermostat housing

26-07-2007, 12:53	#242
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! next i fitted the new water pump... part of the timing belt cover is also retained by the same bolts that hold on the pump so this goes on at the same time

26-07-2007, 12:55	#243
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! next i fitted some new manifold studs. then the exhaust manifold goes on... Last edited by TeflonTom; 26-07-2007 at 17:24.

26-07-2007, 15:37	#244
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! had some more goodies turn up today. this kit is quite basic, it just contains the timing belt and tensioner

26-07-2007, 16:00	#245
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! next spark plugs go in! then fuel rail and injectors then the throttle bodies here's a different view of the bodies, you can see that they have been drilled for fuel injectors then plugged, this is handy for me if i ever decide to fit another set of injectors

26-07-2007, 16:03	#246
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! it's all coming together finally, starting to tie up all the loose ends now... i've even found a suitable fuel pressure regulator, came out of a mondeo with a 2.0 zetec engine.. camshaft not arrived yet but should be here tomorrow

26-07-2007, 16:52	#247
WoodieGuthrie Briskodian Join Date: Jul 2006 Location: Glasgow Posts: 813 Members Car: Totally Stock:-) Thanks: 6 Thanked 29 Times in 23 Posts	Re: OMG! It Begins! WOW! inspirational.-excellent work, I'm bloody jealous!

27-07-2007, 08:52	#248
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! right then folks..... i'm off to skospares in poole...... update later

27-07-2007, 17:34	#249
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! picked up a few bits and pieces today.. got a pair of front hubs, going to strip them down and measure them up ready so i can make up some brackets for the big disc conversion. here is the right hand engine mounting bracket the one on the right is the one for the 6n polo, the one on the left is for the felicia, you can see the similarities bewteen them, they both use the same mounting holes in the engine block

27-07-2007, 17:35	#250
TeflonTom Briskodiodion Join Date: May 2006 Location: Hayling Island, Hampshire Posts: 8,240 Members Car: Fabia 2.0/Felicia Thanks: 48 Thanked 233 Times in 205 Posts	Re: OMG! It Begins! here is that bracket fitted to the engine block

Project Q-Felicia

Project Q-Felicia

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