My V8 Capri Winter Work

[Coops]

well with Caprisports help we have now another engine to play with
more info when we have the block tested,

Also a few of you have been asking on the old forum when will this new brake package be fitted, this will be later this year, i think the plan is before march/april time ready to show it all off at this years shows,

Also i hope to have the new exhaust 'X' pipe fitted and running for this year,

Also hope to have the one off caprisport strutbrace on ready for the start of the show season complete with bonnet gas rams,

Also i hope to have the new VEMS EGT/af ratio system fitted and running for start of this years show season,

so as you see i have a few things to keep me busy (and the guys at Caprisport )

[Coops]

started to strip it down ready for pressure testing to see if it has a liner problem,











As you can see the block is very clean inside,
and to my surprise when i removed the sump it has ARP main studs, (one less thing for me to get )
It seems to have had the crank etc balanced as there are a few polished marks (shiney metal) on the crank and some fresh drill holes (as in picture)

And has anyone seen these pistons before???
only markings are as in the photo's
9525 and GPM











Im desperate to locate some rings for these pistons now,
As once the block has been tested and if all is well i can start the rebuild etc.

[Coops]

thought i should update this post,
the 4.1 engine has now been sold on,
and we are thinking about building a high comp 4.6 engine, but thats in the near future as funds allow,

SO for the time being we are going to tune the 3.9 even further:
we have a pair stg3 heads,







and pic of the inlet





I ordered a crower 50233 camshaft, and a set of crane hi-rev anti pump up lifters from Paul at www.v8tuner.co.uk





the pistons need valve reliefs now as the cam lift is too high,

Latest pics today,
no turning back now engine in strip down mode ready for the new goodies,

[Coops]

Update 01-04-07:

I got the reliefs cut today in the end, the exhaust one is very close to the piston edge though,
but they are now all done, that was the hard part, can now start reassembling the engine,



Stg3 head on just for a picture


tomorrow(monday) i will fit and dial the cam, weld the 02 sensor boss in the drivers manifold and give both manifolds a coat of heat resistant black paint,
fit manifolds and hope to get the heads back on along with the servo reiftted.
then set lifter preload.

[Coops]

update 02-04-07

not every thing went to plan today.
the head gaskets were the wrong ones
so had to sort that out which put every thing behind today,

BUT:
getting crower cam ready for install,


Setting number 1 pistons at TDC ready for cam dial in,


TDC


Lifters now fitted


close up of lifters along with cam lube,


close up of installed Duplex timing gears.


Correct head gaskets.


Stg3 heads now fitted along with adjustable pushrods.


Tuesday i hope to, finish the exhaust manifolds and paint, fit the new water pump and etch prime and paint the pump and timing cover, fit the rocker gear, and set preload, fit the manifolds back on,

which should leave for wednesday/Thursday fit rocker covers and injection fit servo fill with water prime oil pump and fire up and take for a test run.

[Coops]

Update 03-04-07

Well today got off to another slow start,

First job was to clean up the rocker gear,
the ones that came with the heads were newer but still dirty,

a bit of soaking and tlc and they look like new.

and then fitted to engine,


Welded the extra sensor bungs for the egt/af gauge in the drivers manifold, and wire wheeled and painted them both,



stripped the old paint from timing cover BORINGGGGGGGGG.
then degreased etch primered and then top coated


need to clean the gasket faces up now before oil pump and water pump are fitted.

all that is left now is, fit the exhaust manifolds once gaskets arrive,
set lifter prload, fit rocker covers, fit servo, fit timing cover and water pump, fit dizzy, fit efi system, fit radiator,
fingers crossed if things go well next two days i will be at wheels day on good friday.

[Coops]

Update 04-04-07
work as ground to a halt big time.
i set the preload, and turned over by hand ok,
fitted the inlet etc and then primed the oil system when i went to turn over again i noticed it was hard when at full lift thus when i noticed how squashed the valve springs were, it looks as if we may have the wrong springs on the valves




went and counted the coils on the 4.6 heads,
either i am counting them wrong,
or both heads have the same amount of coils 6.
the 4.6 coils are 0.166 thick
and the stg3 ones 0.168 thick
some thing tells me these aint uprated springs

looks like i am off to RS in the morning for a set of TLR50 uprated springs,
two more head gaskets and another inlet gasket
starting to wonder is it all worth it

Oh the progress before we ground to a halt.

timing cover, with waterpump and oil pump fitted.


and fitted on the engine:


setting preload with wire gauges (before problems):

[Coops]

Update: 05-04-07
Went to RS today and came back with some goodies


to find out when stripping the rocker gear down that one of the adjustable pushrods is bent



So had to go back to RS again today, this was getting expensive, two trips to Uxbridge on the same day,

Right,
got home around 5.30pm from realsteel (for the second time),
a day wasted bugger all done

the new pushrods need cutting down and the ends pushing in,


removed one of the valve springs and offered it up to the new ones,
and yup they are 6 coils, i did count them correctly.
old spring on left new RS ones on right.


head fitted with old springs,


heads fitted with new springs,

[Coops]

Update: 06-04-07

finally got round the garage at around 2.30 pm today
and was pleased with the progress today.

Pushrods shortened and new ends fitted by Neil at Caprisport (ta mate)


One head fitted along with pushrods, other head studs coated in ARP assembly lube,


Both heads fitted, Preload set, oil pump primed and engine turned over by hand to check clearances, and yup we have clearance, then tried on the key and no horrid noises
Inlet fitted and dizzy fitted,


All electrics connected to efi manifold, servo reffited, both manifolds fitted to block and connected back up to main system, engine bolted back onto engine mounts and sat back in crossmember, alternator fitted and fan belt adjusted, radiator refitted.

[Coops]

Update: 07-04-07

its alive its alive
needs a bit of tweeking on the ecu, but by f@@k it goes well

needs a new set oil pump gears though as the faces of mine were a bit scored and so was the gear faces, as the oil pressure is a bit lower than prior to me replacing every thing,
i will see if i can get some gears before next weekend, failing that the car runs good, pulls right up to 6k with out any hesitation at all
a vid of the first start up,
http://media.putfile.com/Fire-up-29

[Coops]

Update: 08-04-07

it's refusing to run today,
changed the plugs as thought this was the problem, but still only runs on a few cylinders,
need to dig further as it looks as if we have an ecu malfunc.

[Coops]

Update: 09-04-07

My mate came over today, as we thought a fresh set of eyes may find the fault,
we fitted new plugs and did some tweeking but after 3 hrs he too was beaten, as every thing on the ecu was correct,
we updated the ecu software to the latest tuning and firmware updates,
but this made no difference,
we came close to calling it in, and started checking the vaccuum system for leaks, this is when we found a split vac advance diaphram on the dizzy,
we removed the dizzy and manually moved the base place and got the car to sort of idle, which looks promising, (at last)

[Coops]

Update: 13-04-07
heard back today from the company i ordered my vac unit from that it is stuck in customs, due to a paper issue, (lost the customs paper work)
so until they find the paperwork they can not send the parts tp Paul, who in turn can't send them to me just yet

this car is getting to me slowly now,
just hope this is worth it, got it all to go through again soon when we have the brakes done, BUT caprisport (fingers crossed) won't have any dramas like i have had,
The MOT is due in 5 weeks, got a lot to do in a short time

[IanD]

She's comming along a treat,sounds sweet in the vid mate Can't wait for the day when I get the flippin Cossie running

[Coops]

Cheers mate,
will be better once this fault is cured.