[Fred22]

Table of contents
1. crank pully removal
2. engine strip down
3. forged pistons/uprated headgaskets
4. new timing kit
5. crank pully removal pt2
6. bearings & bolts/fidanza flywheel
7. dmd/coil/header gaskets/head bolts/water pump/ngk
8. poly wishbones
9. 3.0 uprated baffled oil pan (sump)
10. gearbox stripped/big brake info
11. bearing removal/inspection & ford l.s.d.
12. l.s.d instal/stage 3 clutch
13. high flow y pipe
14. piston info
15. bearing/forged pistons/bottom end install
16. brembo info
17. headgaskets install, metal water pump info
18. st170 brake info/upgrade bits
19. wheel width info
20. y pipe pics/ washer/spacer pics
21. timing cover seals/gaskets install/mk3 calipers
22. mk3 calipers painted/17" alloys
23. rear brake upgrade info
24. turbo timer/roll resistors info
25. stage 2 driveshafts/st220 valve info
26. st220 valves info/turbo timer/mount
27. v6 timing done/spark plug install
28. crank seal/fidanza/clutch/release bearing/starter motor install
29. cossy rear caliper info (also pg 30)
30. AFR gauge/alternator + bracket/dmd pully install
31. alt bracket info/stripping car for engine removal
32. engine and other parts stripped
33. old engine removed/new uprated engine installed
34. engine parts installed
35. mk3 rear upgrade info
36. uprated fuel pump info
37. header info/engine removal info
38. turbo pipes & engine reinstall info
39. cat copper gasket info
40. turbo kit arrives...AT LAST!!
41. header pics/refitting complete/engine fires up!!!
42. door pod/race tube/master cylinder installed/car drives
43. turbo info/contour bra info
44. contour bra info
45. svt pistons/st200 engine/rear brace info
46. samco hoses/svt pistons/accusump/rear brace info
47. lambda sensor info
48. new oil pump/3.0 uprated sump/turbo drain info
49. v6 st200 engine rebuild info
50. svt lower manifold info/cossy 18s
51. IAT mod/uprated fuel pump mod/focus rs alloys
52. leather seats/booster pipe/oil catch tank/boost gauge/brembo mod
53. brembo info/boost & oil gauge info
54. forged hybrid info/pillar pod mod
55. pod mod/koni springs/camber kit info
56. turbo info/camber info
57. camber kit/front & rear drop links/brembo info
58. hybrid info/front drop link info
59. camber kit info/red stuff pads
60. pillar painted/brembo pad change/brembo parts
61. race radiator/camber kit/drop links info
62. geometry info
63. power run info (percy's) ford front badge info
64. pad change/battery relocation/strut brace info/mk3 rears painted
65. strut brace/links/full lowering suspension/camber kit fitting
66. spring change/camber/brace info/ rear arb bushes change
67. anti-moose pipe/front arb bushes installed/obd2 info/mk3 brakes
68. rear arm bolts removed & greased/mk3 handbrake info/motul oil info
69. 3rd brake light mod/brake upgrade/race tube fitting
70. exhaust fitting/brake bleeding/brembos/focus rs alloys fitted
71. mk3 rear brake info/spigot rings info
72. mk3 battery info/mk3 brake upgrade mod/hand brake mod
73. mk3 rear upgrade finished/18x8 alloys fitted
74. uprated oil sump turbo mod/battery tray mod/turbo fitting started/
74. 42lbs injectors swap/tr6 spark plug installed/
75. turbo feed mod/oil drained/front bumper removal how to/light removal
75. coolant drain/radiator/fan removal/pollen filter change how-to
76. lambda sensors replacement/turbo kit modding/power steering removal
77. guide replacement/oil pump replacement how-to/retiming engine
78. oil catch tank/samco hoses install/egr blank mod/turbo mods
79. turbo fitting (cont.) battery relocation how-to/fuel pump change
80. turbo and intercooler fitting
81. front splitter mod/front bumper/header tank fitted/fires up!!!!
82. gaskets installed/blowing stopped/turboed st24!!!
83. car dropped at remap place being remapped
84. turboed 3L hybrid info/mikalor clips info
85. remap info (megasquirt)

 

[Fred22]

hi guys im at the stage of taking off the crankshaft pulley but i need to lock it down to turn the bolt anticlock wise to take the bolt off, now i dont want the mark to move so what tool do i need to lock it down, where do they sell it? I think one was being passed round from one megger to another, does anyone know what tool it is and how to borrow it, or buy it even? Any info appreciated thanks

ok managed to take off the bolt, now how do i take off the pulley, im guessing a pulley puller, is there different sizes of pulleys or would any one be ok? Any info appreciated thanks

 

[Fred22]

well got a pulley puller from halfords but the bolts are the wrong size, it just doesnt want to fit to pull it, and it suxs as in the haynes manual the man is using one to take it apart, does anyone know how to take it off please, i know a couple of people whove done the dmd pulley switch so they must have gotten it off someway any info appreciated

 

[kamikaze !]

mine split when i done mine

 

[Fred22]

what did u use to take if off please, as said i looked in the haynes manual, its got a pic of the same pulley that im using except mine doesnt fit, stupid thing it looks too big for the holes to fit too, im thinkin of using a hub puller, just dont wanna waste too much money on a stupid pulley, any help appreciated thanks

 

[Fred22]

right went to halfords again and got a 3 leg pulley the big 6 inch one instead of the 4 thinking if i get the small one and it doesnt fit its back to square one, so got it didnt work at first on the long bit, changed it to the small one, and presto it worked, and its on a thin key way thats on the crankshaft itself so the pulley can only go on and off one way

pics to follow, off with the covers and the chains next :shocked:

:beer:

 

[Fred22]

right ive just tooken off the rear chain tensioner + guide, for future reference, watch your fingers, cause the guide is under pressure and when the last bolt comes off from the tensioner it swings to your left pretty fast :shocked:

tooken off the sprocket and timing chain off, not too bad actually

forgot to mention that theres a fixed guide near the inside of the V and thats held on by two bolts and slides off the bolt in the middle, easy peasy

 

[Fred22]

same thing on the front bank, just for future reference, the front bank is the one with the oil cap on and the rear is the one with the coil pack just for info

 

[Fred22]

also as mentioned in another post, u dont have to undo the sump, i am as im gonna get to the pistons but that will come later

but on the front where the timing chain cover is, theres two bolts, i undid these two only and the cover came off easily, i think they r both holding the cover to the sump but only them two so thats why if your only doing the heads that u dont need to take off the sump

hope this helps :L

 

[Fred22]

next to remove is the cam cap bearings, theres 4 of them, they will be 1L 5L 1R 5R you have to undo these first, well the lefts will be on the front bank (oil side) and the rights will be on the rear bank (coil side).

then undo the bolts holding on the camshafts in the order of the haynes manual

 

[Fred22]

to get to the head bolts, u need to take off the camshafts, id do two at a time as in the front bank and then when your finished with them put them back together on the bench and do the rear bank nxt so as to not get mixed up, the front bank has the waterpump pulley, now the pulley doesnt have to come off, but there are two bolts that are holding a housing to the waterpump pulley and to remove that camshaft u need to undo these bolts then romove the housing and then the camshaft can come out, but in gonna cheat here and just move the camshaft a bit to the side to reach the head bolts, remember use the sequence shown in the haynes manual or else :nunu:

 

[Fred22]

the size of the head bolts r 13 m use a big extenstion and another tip, ive got an electrical impact rench, i could kiss that tool for all the $hit its bailed me out of before, and its really handy to break the hold of the headbolts, im like superman but man even thats a [email protected], i couldnt find my wheel bar to crack off the nuts on the tyres, mind u sayin that i bet theyre in the little corsas trunck as ive done the brakes on them a couple of mnths ago :doh:

but as said a breaker bar would do the job easier i bet but easiest is the impact wrench, then just lift the heads off the engine, as said i promise pictures will come

 

[Fred22]

just a tiny note before removing the heads, theres one 13mm bolt holding on a flange that is connected to the dipstick pipe, undo that one and rock the heads back and forth and they will come off

 

[scottdog]

Fred mate you have done all that and wrote all this :} :} :}

 

[Fred22]

when removing the headgaskets, theres two holes where the gasket slots in, its a black plastic gasket and where those two holes are the gasket has like locking clips on each of then so if your gonna reuse your headgaskets watch out and be careful pulling the gaskets out, mind u if your at this stage then its probrably because your headgaskets are gone and your not gonna reuse them and also its probrably good practice to replace them while your there, but still make a note of the gaskets, dont just rip them off, cause u can inspect them and see where it was blowing from

comes in handy to see where the problem areas are :L

 

[Fred22]

Fred mate you have done all that and wrote all this :} :} :}

sorry buddy, its nice to have wireless internet and laptop, ive got my oldies on the music :naughty:

and i can step by step u as i go, only thing is the laptop is gonna be dirty now :doh:

its for mine and yalls reference, im a busy boy after getting past my obsticle of the pulley :banana:

 

[Fred22]

dont know if i mentioned this but once the headbolts are off the heads, refit the cams with the camshaft caps, 2 bolts on each cap, 18 all together on the front head

forgot to mention the cap bolts are 8mm for reference

 

[Fred22]

its probrably a good idea when u have the heads off and can see the piston heads and cylinders to clean them degrease them vaccum them what ever cause man theres [email protected] that manages go get in there and its not good, i found a metal connector in there :shocked:

but over all everything ok, headgaskets are fine, no leaks, no cracks or breaks in the gasket, the pistons and the valves look fine, no bents in them but because ive got another set of heads and cams and pistons to put on it doesnt matter i guess

but for yall only replacing the headgaskets, clean them good, take some time doing it, polish the damb things as well lol dont be lazy either, its not that many times your in this situation :eyesup:

 

[Fred22]

another good thing to do while your there, refit the crankshaft bolt and turn the engine to see if u can hear anything wrong in the turns, no.1 cylinder piston will be up, 2 and 3 will be goin down, 4 and 6 will be down in the front bank and the one in the middle no.5 i guess is up as well, looks cool turning it as well as u can get the top of the piston cleaned

 

[Fred22]

right guys progress is gonna stop now, cause i need to get this crane tommorow and then its back again, i wish i had these headgaskets now but i will email the man again tonight :angryfire:

just finished hoovering the engine pistons out, shame on the person who had them before, :nunu:

but at 40 pounds for the lot i dont think that was too bad

if anyone has any questions feel free to ask me on this, ill try to answer the best i can on this, but anyone wanting to do this job, dont be afraid to do it thats what i wanna say, its been an experience to do this and its been quite fun, i like doin stuff like this

as promised ill put pics up as soon as possible :L