More work & £££ !

[mikeb]

looking good..........how did you get on?

[MattD]

Passed

Good to get back in the saddle...

Brake bias needs sorting. It stops, but could better (can't lock the fronts)
Front end needs setting up &/or ARB needs fitting, which requires some thought.

Power is strong but smooth delivery, spins up when floored in 3rd.
On the base setting, so 240hp, very driveable, driver focus required - unlike the 180 Zetec, which I could drive flat pretty much anywhere. Suspect with the full 270 ish she'll try to tell me she's the boss.

Overall, a good step forward, with more to come.
Oh, and the taller aeroscreen works.

[Antnicuk]

good to hear Matt

[MattD]

Well.... something had to happen didn't it !

I was intending to do Rushmoor sprint last weekend, but instead ended up looking under the bonnet.
And I've done a proper job too.

Driving to work in the Stylus a week or so back I was following a Golf R32, when the slow traffic disappeared so we both booted it.
About a mile up the road, on boost & somewhere quite a way north of the limit something let go.

Cue nasty rattly noise. Originally I thought I'd done something to the turbo, but on closer inspection its a crank bearing.
Engine is still in, but with head & sump off. I think I've been lucky & the top-end is OK
Problem is the crankshaft journals should not be ground as the surface is nitrided. Means the one sitting in the car is scrap.

Probably the quickest route back onto the road is to find a spare engine - I'm now on the look out for a Lancia Thema, Integrale, or Fiat Coupe 16V Turbo lump.
Plus a spare crank for the current engine so I can rebuild it later.

Anyway, still a bit peeved, but its self-inflicted really
I've got 6 weeks to sort it, or it also messes up my Le Mans road trip

[stylussprinter]

That's a real sod Matt What about a Nissan turbo possibly cheaper

[MattD]

That's a real sod Matt What about a Nissan turbo possibly cheaper

Its OK, I have a couple of potential leads for another road-spec lump.
Have also found a good used crank.

So I have options, its just the time factor that's the pain in the RS.

Going Nissan (or maybe even R1 ) will take longer & to me would feel like giving up too easily.
Just means I'm spending my suspension upgrades funds elsewhere

[MattD]

Had a long day in the garage today

Complete engine de-plumb, de-wire, & drain down. Then lift out & gearbox split off.

Tomorrow will be swapping the different bits from one engine to the other.
Have a choice of 2.0 Sierra or 2.8 Capri Type-9 to go in.
Was holding the 2.8 back to take to BGH, but the 2ltr that was in is well worn.
Pretty sure it'll be the 2.8 being fitted.

If I can get it back together by Monday night , if its running

As a bonus I've got 90% of the Weber Marelli MAP based management system, just missing the TPS & idle control valve.
If I feel like it later, that would be quite a step forward from the old Bosch airlflow meter system it was (& will be) running.

[Antnicuk]

thats a shame Mat, have you found out what caused the problem? the last thing your want is it happening again. Have you had it mapped to make sure the AFR's are ok?

[stylussprinter]

Matt What's the significance of '' by Monday '' I knew you were off to the Classic LM but that's June Don't think Sharon's ready for a Stylus long haul yet

[Bikenuts]

Matt,
Doesn't the 2.8 box have a different length input shaft?

T'other Matt

[MattD]

Matt,
Doesn't the 2.8 box have a different length input shaft?

T'other Matt

It did before I cut the shaft down to size.
Had the 2.8 box behind the Zetec before.
The gear ratios were much better suited, just the 1st gear is a bit short.

[MattD]

Matt,
Doesn't the 2.8 box have a different length input shaft?

T'other Matt

It did before I cut the shaft down to size.
Had the 2.8 box behind the Zetec before.
The gear ratios were much better suited, just the 1st gear is a bit short.

Sorry Matt, didnt mean to be quite so terse in reply
Was just abit focused on the job in hand !

[MattD]

thats a shame Mat, have you found out what caused the problem? the last thing your want is it happening again. Have you had it mapped to make sure the AFR's are ok?

Hi Tony... U still lurcking ?

Not really analysed the damage yet, nor the reason's why. Will pull the outgoing engine apart once the replacement is up & running.

As the bleed valve has effectively removed the turbo boost safety features, I suspect this is the partly the cause (plus right foot)
The boost solenoid would limit sustained boost for a few seconds, but as this has been removed, I think foot hard down for 15-20
might have something to do with it.
Something had to give I guess, a big end or piston ring I think.

Mapping is a problem at the moment, the OEM airflow meter system is locked, so the maps can't be modified.
The later WeberIAW MAP system I have the bulk of is also locked but can be unlocked via the Integrale forum guys.
Either that or fit a Emerald/Omex/DTA or MOTEC aftermarket MAP based system.

For that reason the engine going in is running the standard smaller turbo, whilst I decide on the best way forward.
That way the MAP system can go straight on to the car & be fettled later.

Anyway... what have you replaced your Stylus with ??

Rgds
Matt

[MattD]

Matt What's the significance of '' by Monday '' I knew you were off to the Classic LM but that's June Don't think Sharon's ready for a Stylus long haul yet

Hey Rob
Nothing behind "by Monday" really, just that I have a job to go to today
Ran out of time any way. A couple of little jobs to do & then its ready to go in.
I needed another hour or two, it just wasnt worth starting the lifting & fitting yesterday

Its LM 24hr in June were going to, the Classic is in July.
Main thing is I want to drive the car a few miles before committing it to the ferry - & only 4 weeks left to do that !!.
Sharon's fine with the Stylus drive, its the camping she's not looking forward to

[Bikenuts]

No problem, just didn't want you to come a cropper.

T'other Matt

Matt,
Doesn't the 2.8 box have a different length input shaft?

T'other Matt

It did before I cut the shaft down to size.
Had the 2.8 box behind the Zetec before.
The gear ratios were much better suited, just the 1st gear is a bit short.

Sorry Matt, didnt mean to be quite so terse in reply
Was just abit focused on the job in hand !