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My General ramblings, mostly car related
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Stage 3: 1242 time baby!

Posted 13-04-2007 at 15:25 by Luke

At long last, the time had come to 1242 the cinq. Id got all the tools, had all the necessary parts bought/cleaned/machined and already home ported my head and cleaned/reground all the valves over the previous 2 weeks.

So, lets start with the general build process as a summary...
  • Remove the old engine
  • Take off the water pump, oil pressure switch and alternator off the old engine and put on the new one.
  • Take cam out of the old head and put in the new head (and shim it all correctly)
  • Fit new clutch kit and new clutch pivot arm bushes.
  • Refit new engine and gearbox.
  • Modify exhaust manifold and replace all ancilleries (inc. new sparks).
  • Refil gearbox oil, engine oil, water.

Out with the old

By this point id removed the head, driveshafts and most of the linkages ready to drop it out with the engine crane.

By the looks of the old engine, i had a leaky core plug and there were alot of oily carbon deposits on the piston crowns so the valve stem oil seals or piston rings werent sealing properly. Never mind

Rebuilding the engine

New clutch fitted (aligned by eye and it went on perfect first time ) and the water outlet pipe fitted and sealed after painting it.

Mated the gearbox back to the new engine, and all seems well. I also cleaned up the gasket surface on the block using some 800 wet'n'dry with some wd40 to stop it cloging up - came out perfect .

Then new block put back in!

New head

Fitted the 75 cam and shimmed it all within the 0.5 tolerances using the shims from both heads. This has been skimmed and cleaned, valves reground, home ported to the gaskets and exhaust ports polished as well as i could. blew up my trusty dremel in the process

Fitted the intake manifold and new thermostat.

The head fitted, torqued down and throttle body fitted.

The modifications
For the engine to fit, i needed to use a spacer for the exhaust manifold. But i also had to elongate the studs on my manifold. After attempting to get the studs out of my old manifold, i gave up and used a spare i had lying around. The only problem with this one was one had been broken and drilled out to the point where i couldnt re-tap it - so had to use a bolt instead. the other 2 were threadlocked in place and then painted the manifold. Once dry it was ready to be refitted...

Back on the road!
I refitted all the ancilleries back and refilled all the fluids. sadly i didnt take any pictures as it was getting dark and had to work under torch light - which was fun to say the least. I came back the next morning and did the final touches and put it back on the road...

Luckily it started first time, with no problems. had a slight coolant leak, which was due to me forgetting to tighten a hose clamp on the back of the throttle body. Was also a small oil leak coming from the crank area, but think it was just runoff from where i spilled some re-filling. Will keep an eye out.

As it was still nice and warm, it was perfect weather for a wash/polish and wax to get rid of all the oily fingerprints and paint splatters from the work above. Yellow cars always polish up lovely

Final thought / First impressions

I was pleased with how it all went, taking me 2 days to do the whole lot by myself taking my time so everything was nice and clean

Im still running it in, so not had a chance to really open her up yet, but the torque difference is amazing - much more lower down and is really usable. It made it to ACE and back with no problems (covering around 110 miles), didnt overheat at all

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  1. Old Comment
    MultiplaAbarth's Avatar
    Nice story, reminds me of my old 1050 127 Sport, small engines=loads of fun but no torque, "theres no substitute for cubes"!
    Good luck with the build....and turbo...

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    Posted 06-07-2007 at 00:10 by MultiplaAbarth MultiplaAbarth is offline