My New Engine Build

[Ninka]

Ohh :ooops: now a 1992 BA XR6T, that would be REALLY rare - Well spotted, it's a 2002 model of course, originally with 4sp Auto, factory leather interior and premium sound with colour screen, but since then modded a bit

[45T-XR]

Any progress mate, did those screws turn up. Cant wait to hear more

[Ninka]

OK finally time to report some progress....

Yes the bolts did finally turn up, and the engine could be completed.

Monday this week was the day to start the 'heart transplant' on my girl, and as expected she was a little apprehensive, it's major surgery after all

Doing this on my own, it's pretty much a 3 day job, with day 1 being spent on disassembly/disconnection of the engine from the car, which in broad terms involves:

1) Removing all electrical connections

2) Removing all intake and exhaust piping

3) Removing front bumper assy. incl. under tray

4) Removing Intercooler

5) Unbolting aircon. condenser from radiator

6) removal of cooling fans & radiator with associated hoses and expansion tank

7) Remove starter motor

Unbolting torque converter from flex plate, engine and trans. cooler from transmission and engine mounts from cross member

9) Lift engine out

Day 2 is pretty much spent moving all the external bits and pieces from engine 1 to engine 2, as well as tidying up a few issues I wanted to improve, as well as lifting the new engine into the car.

Day 3 I spent doing all of day 1's activities pretty much in reverse, and in the process obviously fitting new Iridium plugs (gapped to . new oil filter (pre-filled with oil) and new coolant.

Before starting the engine, I put my big charger on the car, and ran the starter motor for quite a long time, to ensure the oil was as close to all bearing surfaces as possible, before starting the engine for the first time. This process also serves to get a bit of fuel through the injectors, as they are firing while engine is cranking.

After fitting the plugs and everything else needed, I held my breath and cranked the engine which started immediately, with oil pressure also present virtually immediately, so a great result.

Well I know it's early day yet, and there is some running in to be done (as I am writing this, I have done just over 100k's) BUT the sound of this engine is absolutely amazing, with NO mechanical noise whatsoever, and I would almost swear that it is as quiet, if not quieter than a stock unit (well maybe except from the deep rumble emanating from my 2 x 2 1/2" exhaust) :sungum:

Driving the car the difference is noticeable, with less NVH somehow, and definitely more vacuum at off throttle downhill running, and at full throttle, well the tyres squeal and SHE SINGS.

So far very happy with this build, and the lessons learnt over quite a few attempts at this now, have certainly taught me a lot about what makes a nice sounding engine, and one which is almost unbreakable at the power levels I run.

Pictures attached.

[tray_182005]

Nice work mate

Always want to no how the cosworth piston went

Looking forward to seeing the end result mate well done

[Shyfrd]

nice update, very clean

[Gasman]

very tidy Engine bay

[discostig]

Great read. Looking forward to being impressed on the cruise, hope you do make it!

[Ninka]

Well, I am now heading for 750k's on my new engine, and (stops for a second, and thinks about what I am about to say.......) I AM HAPPY WITH MY ENGINE FOR THE FIRST TIME IN YEARS :biglaugh:

Thumbs up to Atomic for supplying me all the bits and pieces, incl. a good checked and honed block, as well as the Cosworth pistons, they are awesome so far.

Edited 20/12/11 01:53 PM by Ninka

[discostig]

Nice one! Quite the journey you have taken with your humble 2002 BA, must be very rewarding.

To everyone else, it sounded great on the cruise just so you know .

[louiseanddanny]

Hey Ninka ! Congrats on the awesome build ,I was hooked as soon as I read the first post! great read and advise your expertise will help a lot of people.