Well, I thought I should post up what's been going on with this. It's all running now, doing my running in miles, and going to be doing my first oil change today after a successful first 100 odd miles. Few little things to tidy up, but here's the progress from the start...

Basically, the big end bearings went on it and the bore was scored on one of the chambers. So it was time for a new block.

The inspection:

Off came the sumps to see what was going on at the bottom.


Well, that doesn't look too healthy does it...


Time to get the head off...






Oh dear, there's the scoring...


Looks a bit worse for wear


Well, obviously the engine now needs to come out and get rebuilt. Like I say, a new block was sourced, and a few parts needed. So out with the old...



Quite hefty with the gearbox and transferbox on...


Gearbox off...


And now let's turn it upside down and have a better look at the crank with the piston end caps off...


That's not right


Some lovely crushed bearings...


One still intact on the left, 2 crushed ones on the right...


Diagnosis complete, time to go and get the parts needed

_________________


Quote Clarkson, Top Gear, 17th July: "I'm not having a stroke... just driving a Nissan!"
Quote Ry, Mallory Park, 3rd Dec: "Ahhhh crap... Just a bit too over eager really!"
"I used to be an adventurer like you, but then I took an arrow in the knee"

The rebuild...

Well, after looking at my budget for the car, forged pistons were not an option. The standard internals can take up to 350bhp anyway, and I'm not going to be chasing any more than that just yet, so why bother spending so much on forgies when I couldn't really afford to? So I just uprated whatever else I could.

This included ACL race bearings, ACL main bearings, and ACL thrust washers, and multi-layered steel exhaust manifold gasket. Everything else was considered but as said, I only need standard items for the rest. So I got new gaskets, head gasket, oils, filters, chain tensioner, and the crank had to be reground as it had some slight scoring. The crank is hefty enough to take some grinding without weaking, so 0.25mm was shaved off and I got oversized bearings to match...



Now, the block I sourced was black. I don't like black, how you supposed to see oil leaks?? So a clean and repaint was needed...





Then I got the crank and pistons in with all the new bearings...




I cleaned up a few parts here and there, but I was losing patience with cleaning and just wanted to get the thing built so I just carried on with whatever I had... sumps on now...




Oil strainer in...


Baffle plates on...


Mmmm, clean, and no metal shards in there now!


And then came the head. All went on, no pics of progress, just the end result...




Timing chain FTW...


Starting to look like an engine again now...




MLS gasket on...


Turbo on...


Inlet and most ancilliaries on...




Then it had to come off the engine stand, onto the floor. I used a bread tray for manourvering the thing about, awesome bit of kit




Transfer box back on...


And the gearbox...




You may have noticed I took the inlet back off. This was to allow the engine to slide under the car, ready for it to go in. I wouldn't have got the clearance with that on!

_________________


Quote Clarkson, Top Gear, 17th July: "I'm not having a stroke... just driving a Nissan!"
Quote Ry, Mallory Park, 3rd Dec: "Ahhhh crap... Just a bit too over eager really!"
"I used to be an adventurer like you, but then I took an arrow in the knee"

Getting it in...

Well the enjoyable stuff was done. Building the engine was fun. Now comes the graft work, getting it into the car, and this is what awaited me...





Wheeling it under...


Clearance was tight as you like


Then the inlet goes back on whilst it's under the car but before it's mouted up to make my life easier, and all the engine loom is plugged in...




Not a lot of room to manouver...


But after a bit of faffing about to get the mounts lined up... she's in!


After hooking everything up, putting everything back on, filling it all up, came the moment of truth. The coil was disconnected and fuse for fuel pump taken out, turned it over to get oil pressure, and plugged all that back in, and the first start commenced.......

VROOOOM! Yay! It worked!

Good pressure, no knocking, all good!

Nearly. Idle wasn't right. Fault code check brought up coolant sensor. So that got changed. Made no difference. Fault code then brought up MAF sensor, swapped with a known working one, was fine. That fault code disappeared and never came back. It was hunting up and down like a bitch. Checked for air leaks, but nothing. I was stumped. Off came the inlet (bitch of a job to do in situ, but I've now got that down to 25 minutes!), and all the sensors were checked, as were the wires to each one. Still nothing.

My breakthrough came when I changed one of the IAC valves at the back. I'd opened it up and the spring loaded disc was very stiff and sticking at it's furthest point. So sorted that, and the hunting went. Wooo!

Anyways, off it goes for it's MOT and passes first time! Not bad for a car approaching 20 years old now!

So yeah, there you go. Just running it in now, and it will be running boost soon enough!

No current pics, but here's how she stood just before it went bang...





That is all. Hope you enjoyed reading. If not, you shouldn't have bothered getting this far, so naff off!

TERRY! Get yours sorted mate, it's hard graft, but you will NOT regret doing it! I'm loving driving the Pulsar again, forgot the attention it gets and how nice it is to drive (if a little bit more hard work though!)

_________________


Quote Clarkson, Top Gear, 17th July: "I'm not having a stroke... just driving a Nissan!"
Quote Ry, Mallory Park, 3rd Dec: "Ahhhh crap... Just a bit too over eager really!"
"I used to be an adventurer like you, but then I took an arrow in the knee"

good story there

glad it alll worked out

Looking fantastic mate. Well done for all that hard graft but I bet it feels worth it now

Cheers lads

Yeah, it's great driving it again. Glad all that work is out the way now. Still got a few things to tidy up, but nothing much. Going to spend some time on it this weekend methinks

_________________


Quote Clarkson, Top Gear, 17th July: "I'm not having a stroke... just driving a Nissan!"
Quote Ry, Mallory Park, 3rd Dec: "Ahhhh crap... Just a bit too over eager really!"
"I used to be an adventurer like you, but then I took an arrow in the knee"

Love seeing rebuild threads. Dare I ask, how many more miles/oil changes until boost?

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Rest in peace Ben "Jam" Elvin. Gone but never forgotten.

After this one I'm doing today, one more then the boost may be increased A few hundred miles left yet... but I'm not rushing it. I'm happy enough driving it round gently and ironing out the little issues.

I know you've seen most of the above, but thought I'd share with the masses and have it all in one place.

_________________


Quote Clarkson, Top Gear, 17th July: "I'm not having a stroke... just driving a Nissan!"
Quote Ry, Mallory Park, 3rd Dec: "Ahhhh crap... Just a bit too over eager really!"
"I used to be an adventurer like you, but then I took an arrow in the knee"

Awesome stuff I bet you cant wait to boost it againt! I wish zetecs had a timing chain, so much better than a belt! You should paint your rocker cover a different colour i think

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looks good
is that lump the same as a almera gti ? as the rocker looks the same lol

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RUST IS LIGHTER THAN CARBON FIBER

http://www.fiesta-si.com
http://www.fiestaguides.co.uk/

i can't see how it is in anyway similar

maybe just the same rocker colour

na me mates is silver lol
it the way the engine looks lol

_________________


RUST IS LIGHTER THAN CARBON FIBER

http://www.fiesta-si.com
http://www.fiestaguides.co.uk/

The almera uses an SR20, but it's not a DET so the rocker covers will look very similar, but I believe the SR20's have some writing on them to them bottom left.

The red is standard so it's staying, but I'm going to get a new one so it's all fresh

Yeah, timing chains are much better than belts. Glad it's got one, although a little more noisy when you listen to the engine.

Thanks for the comments though

I must admit, I gave it a little bit of boost today, just to see what I have to look forward to, and not high revs, just about let it kick in. All I can say is.... ohhhhhhhhhhh my god!

_________________


Quote Clarkson, Top Gear, 17th July: "I'm not having a stroke... just driving a Nissan!"
Quote Ry, Mallory Park, 3rd Dec: "Ahhhh crap... Just a bit too over eager really!"
"I used to be an adventurer like you, but then I took an arrow in the knee"

Sweet thread mate I know what you mean doing the graft but it is a good feeling to get it going again good read that!

_________________


RUST IS LIGHTER THAN CARBON FIBER

http://www.fiesta-si.com
http://www.fiestaguides.co.uk/

Cheers Ade It is a good feeling when you do it all yourself and it works! Nothing like it

Sorted then Rob?

I've been up Bilston/Willenhall in it last week, surprised you didn't hear it from wherever you are

_________________


Quote Clarkson, Top Gear, 17th July: "I'm not having a stroke... just driving a Nissan!"
Quote Ry, Mallory Park, 3rd Dec: "Ahhhh crap... Just a bit too over eager really!"
"I used to be an adventurer like you, but then I took an arrow in the knee"

Great work! I wish my engine was that clean!

Cheers dude. I wish I'd got it cleaner, but I just got to a point where I wanted it in and working. Easy enough to drop the engine again should I want to in the summer

_________________


Quote Clarkson, Top Gear, 17th July: "I'm not having a stroke... just driving a Nissan!"
Quote Ry, Mallory Park, 3rd Dec: "Ahhhh crap... Just a bit too over eager really!"
"I used to be an adventurer like you, but then I took an arrow in the knee"

YAY

_________________

awesome read
love pulsars
my mate got blitzed by one in his scooby n he was like
'all i saw was somethin with a red 'R' flyin past me'
bet youv got a grin ear to ear after the graft im thinkin of a rebuild for my shitty zetec tbh
top stuff

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Fiesta Si 2.0
Fiesta 1.1
Peugeot 206 sw 1.4