Skaven

well ill send you some luck just incase, aye i know the parts supplier are curious, but its nice to see them interested stead of them just being "meh" and not caring

it will be good to see the outcome, ps i think a dark silver/anthracite wheel will look nice

prodriverules

iTrader: (52)

And what do the pictures prove Dylan? Other than I'm pretty sure I can see the little nicks in the seal in the pic,using the seal as a clock it's about 7'0'clock?

DYL 4N

They are at 12:30 -13:00 on Ty's pic.
That was oil from when the seal was fitted.

prodriverules

iTrader: (52)

Fair comment,the detail is to poor to be sure of anything though.

DYL 4N

I will pull another off my PC if it turns on and loads.
I have enough new seals in my garage that if I did damage it I would have changed it.

Cannon Fodder

iTrader: (100)

Yes they could easily have just turned around and wiped their hands of it, but I dare say they are interested as it's good for them to know when their products are fitted and give a problem (whether an installation or material issue) that they identify the cause.

I am leaning heavily towards an anthracite type colour myself as well.

tubbytommy

iTrader: (20)

Pink wheels for me....

Cannon Fodder

iTrader: (100)

I have done Porsche Racing Orange and they were less than a success, they didn't achieve the end result as I was planning on.

prodriverules

iTrader: (52)

Fair enough,but I would like to go back to some of the other obvious issues which I'd like you to explain if you would,firstly the bucket clearance,so your saying they were correct when you checked yes,was this pre fitment of the heads or after installation[both?]
I'm curious as solid lifters simply can't become that out of the tolerance especially in the amount of miles they have done since last being checked,and also what about the tight ones?

The oil catch can issue which resulted in the crank case being pressurised and pushing the gunk seen in the picture into the IC?

The oil cooler pipes you installed which were lay on top of the manifold and the rubber water pipe that was up against the manifold also?

DYL 4N

The oil cooler pipes where laid on top of a sheet metal shield I made. This has obviously come off and gone astray at some point.
The water pipe is a huge oversight by me. I didn't consider expansion in the metal exhaust and the water pressure within the pipe.
Again why would I do this. At the point ty was a regular at my garage as he is in yours. If he came once in a blue moon then maybe but I knew he would return and I didn't want any failures.

The clearence you both have stated are both opposite. One is larger and the other is smaller.
I can't explain that one. These can only be done after the head is torqued down unless I built the heads up and then strip them back down. Ie cams.

The oil catch can as far as I'm conserned is and was not fit for purpose.
I diagnosed turbo because the symptoms looked that was blue smoke and oil in the intercooler. I had never worked with or seen an oil cooler that had an issue.

As they say "you can't train experience"

prodriverules

iTrader: (52)

Tbho Dylan it was more than oversight as the water pipe was resting up against the manifold and had nothing to do with expansion other than when it did expand it was sawing into the pipe.
If the 'shield' came off then it was obviously not secured properly,speaking of which,how did you secure it?attached to the chassis leg?.

When I do clearances I do them on the bench first and double check once they are installed but that's just what I have been taught to do,there is only one explanation and that is you didn't get them right and couldn't be bothered to do anything about it when you installed the parts back into there places or you got the buckets mixed up.


Ref oil catch can,so how come when the plumbing was sorted it was ok for use and didn't push oil into the IC if it was all down to the catch can?

Infected by sti

iTrader: (6)

That's why I asked about the studs Ty as my initial thought was the stud was sitting proud which would indicate something stopping it torquing right down I.e swarf or some other foreign body down the hole, or the stud has possibly picked up on a thread, but you would see that as soon as it was removed

Cannon Fodder

iTrader: (100)

All will soon be revealed as to why the head stud(s) are not seated properly, I am really looking forward to seeing and finding out the reason why.

There could be any number of plausible reasons for this happening, in fact as new ideas are being invented to explain away the problem I would like to suggest that Elvis was to blame or perhaps even alien abduction as they are just as plausible as one idea put forward.

Cannon Fodder

iTrader: (100)

This is another example of the care and attention that was taken when my engine was rebuilt, at the time to save face for the person who installed the timing belt and guide I did not give any details out.

For those that can remember on my first mapping session with Bob Rawle after the running of the engine had been performed I had an 'issue' prior to the mapping session whgich meant it had to be aborted.

The issue in question was actually that the timing belt was damaged due to the fact that it had been rubbing on the timing belt guide, the blue residue that can be seen on the upper belt guide is actually the outer coating from the Cosworth kevlar belt - I dare say even now the inner parts of the timing belt covers have a blue 'tinge' which can still be seen.

It was found because Bob heard something 'odd' from the engine in the timing belt area which was found during his pre-mapping checks, it was only the fact that the belt has kevlar re-inforcement bands running through it that saved my engine - if a standard belt had been used then it would have snapped without issue.

Like I said earlier I decided to save face for someone rather than make the details public knowledge as early on I put this down to being 'one of those things' and I believed at that time it would be the exception rather than the rule.

How wrong I was? And yet again this has been another cost I have had to burden.

This PDF link from Gates makes for a pretty interesting read as well about the importance of making sure that the belt clearance is set correctly

http://www.gates.com/australia/downl...ation_id=18884

tubbytommy

iTrader: (20)

its all power power power with you welsh boys.
just buy one of these..........



seriously though the engine build problems are mounting up, the timing belt guide is a very bad one in my opinion as undetected would eventually have destroyed the whole engine.

prodriverules

iTrader: (52)

I guess it was an oversight as well tubs

stevep360

iTrader: (20)

You have more patience than me Ty. Looking forward to more coming to light, if that makes sense, at least now its in reputable hands it will make the process much easier to resolve.

redwards

iTrader: (6)

Love that sign tubs

Cannon Fodder

iTrader: (100)

I will buy one of those, no problem there.

Yes it could have been fatal for the engine if I hadn't been using a Kevlar banded belt, that is why I would never fit anything else.

Cannon Fodder

iTrader: (100)

That would seem to be somewhat of an understatement if ever I have heard one.

I don't know about patience Steve, mine is starting to run thin now but you are right that now the engine is in the possession of a reputable repairer that it should be plain sailing from hereon in.

You can always rely on Tubby to lighten the mood.

Cannon Fodder

iTrader: (100)

Well some progress today - the engine has been delivered to the repairer, I have made a decision on the head studs and that is to go for an RCM uprated head stud kit plus for the bling factor a set of custom CDF Racing Spec C fuel rails.

Tomorrow should be very interesting indeed as hopefully by mid afternoon I will know the full extent of the engine condition and what is required to get it repaired.

I am prepared for the worst so that anything better than that will be a bonus.

And nearly forgot it will be having Cosworth stopper head gaskets as well.

Cannon Fodder

iTrader: (100)

Well the news was about as bad as it could of been, so at least on the upside I am now going for a 2.1 stroker build on the downside it was an expense that is going to be have to be swallowed.

The reason for the failure is that the head gasket for cylinder 3 (the one under the turbocharger) has been allowing combustion gases to enter the coolant chambers and in reverse allowing coolant to enter the cylinder.

The bore of cylinder 3 shows slight signs of piston ring scrape and where the coolant has touched the bore you can see discolouring, basically this cylinder needs a rebore effectively making the 2.1 engine build worth doing for the extra cost of a crankshaft.

The reason for the head gasket failure is inconclusive, no firm reason can be given although the head studs will be sent away for testing anyway.

Some other issues were found which wouldn't have been a contribution to the failure but certainly weren't shining examples of workmanship either.

A good example being a scrape found at the bottom of the sump where it had been 'chiseled' off and then the resulting gouge had just been filled with more sealant when the sump was refitted, there was a resultant oil leak from this area as well.

I could carry on but it still won't change the fact that the engine has failed and now I have to deal with it, oh well bread and water for me from now on then.

I will post up the details of the spec of the build later, one thing for sure it will be one hell of an engine as it will have the best components used (again).

redwards

iTrader: (6)

Not great news there. At least the decision was pretty much made for you (albeit an expensive one!)

As you seem to have been bit once, at least this build will give you peace of mind when you're behind the wheel.

Cannon Fodder

iTrader: (100)

Having bad news is never easy to stomach even if it's expected or not.

You're right of course about being bitten but I'm starting to feel like a vampire's bitch.

Rally fan 555

iTrader: (7)

You know I feel for you Ty, shocking again !! hope it all goes well and looking forward to seeing the "Goodies" list of parts bring on the Beast

The Stitcher

iTrader: (12)

This thread is moving Quick !!! I can't keep up lol will be back bigger and better

The Sheep Worrier

iTrader: (2)

FFS. 'Nuff Said.

Cannon Fodder

iTrader: (100)

I have had some time to reflect further on the latest disappointment in Impreza ownership Simon and at this point I don't even know if I can be bothered if I am being 100% honest.

This will be another summer period with little or no use from the car other than running in another engine, I have missed shows already and I don't know if I am really that interested any more in Impreza ownership.

I think before I throw another large lump of cash at the car I need to think about what it's worth now, and what it will be worth with a new engine. The sensible answer is it won't be worth any more in real terms and it will be load of cash flushed down the toilet.

I have let my heart overrule my head for too long with this car and it's time to think about this long term.

If I was happy to drive around in a shitter then fair enough but I won't do that so if I have a performance car it has to be well done, and that on this occasion this might just be one step too far.

jayallen

iTrader: (31)

No matter which road you take Ty no doubt it will be the right one...

prodriverules

iTrader: (52)

Stop being a ***** and get the bits bought
AP's are mine though