Welcome Guest [Log In] [Register]
Welcome to the Dorset Japanese Old Crew. We hope you enjoy your visit.


You're currently viewing our forum as a guest. This means you are limited to certain areas of the board and there are some features you can't use. If you join our community, you'll be able to access member-only sections, and use many member-only features such as customizing your profile, sending personal messages, and voting in polls. Registration is simple, fast, and completely free.


Join our community!

If you had membership on the Original DJCC Forum then that account should still be active on this forum and you can log in below using your old username & password.

If you're already a member please log in to your account to access all of our features:

Username:   Password:
Add Reply
Justbutts Engine Evolution
Topic Started: Aug 26 2007, 09:29 AM (783 Views)
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
hi all

just thought i would put a post up on how my car has evolved into what it is now :)

i have done all the work carried out to my car in the performance side apart from the mapping element, and i have spent a vast amount of money getting it to what you see today.

please see my show room photos for spec of car.

the story :-

back in february 2007 i had my car mapped by jez at horsham devlopments to a stage 3a performance tune.
this state of tune allowed me to run 347bhp with 359ftlbs torque at the flywheel on standard nissan internals. thats 295bhp at the wheels :rock:

back on the 15th April 2007 disarster struck when on a routine oil change we noticed a loud nocking noise from the bottom of the engine, yep you guessed it DEATH RATTLE the big ends had started to go !

now i had two leaks for a while one was from my turbo oil drain flange on my old turbo and the other i thought was gear box oil as it was coming from the gear box.

i made the mistake of changing the turbo cause i wanted more power and never really check the engine oil for a while after that. big mistake :(

upon dropping the engine oil we found that there was actually not alot in it :blink:

it turns out the leak was actually the rear crank case seal and the fact that the engine was putting out all this power, having the life beaten out of it each night with not much oil in caused the big ends to give up the ghost. :wallbang:

so out comes the engine

Justbutts Engine Evolution Project

the engine before work began
Posted Image
due to my car being lowered i had to remove the front bumper to allow the car to go up on ramps. the lights have to be removed to get to the bolts that hold the bumper on
the intercooler on the front is an apex performance type 2 intercooler with longer pipe runs so no cutting of the battery tray is required.
Posted Image
airfilter, intake pipes, raditor and fan shroud removed
Posted Image
Posted Image
Posted Image
the car as it sat on my drive for what turned out to be 3 months :(
Posted Image
exhaust manifold, turbo, down pipe, inlet plenum removed and powersteariing pump dissconected
Posted Image
Posted Image
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
my mate woody and the sick engine
Posted Image
engine bay with the engine removed.
Posted Image
rocker box cover removed
Posted Image
big end caps, main bearing caps and bolts
Posted Image
crank still in position
Posted Image
oil pump and timing chain cover removed
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
with the crank removed i could then see which bearings had started to fail.
the number one big end bearing had gone along with two and three. and the number three main crank journal bearing had gone to

Posted Image
Posted Image

Posted Image
number three main journal bearing cap
Posted Image
big end shells showing damage
Posted Image
Posted Image
number one con rod damage outer bearing face. sorry bout the photo.
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
Mark.T
Member Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
Getting down and dirty :) Hope it all goes well :)


Mark
1.8 Eunos Roadster Special Type II
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
cheers its all gone very well still got the odd oil leak but slowly stopping them LOL.
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
the bottom end with the cylinder head removed stripped down and ready to go for machining
Posted Image
top of bolck looking at pistons notice damage to piston heads, damage not to bad could be cleaned up but i needed any excuse to change them and i took it lol.
Posted Image
oil cooler and heater pipe work
Posted Image
damage to number one and number two cylinder head positions possibly due to melted spark plugs back in 2005, rather then det.
Posted Image
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
Stevey
No Avatar
Drift Slag
[ *  *  *  *  * ]
Nice work B) .... Damn fast car :)
200sx S14A - Stage 3A - 350bhp - Sold

Rx7 FD3S - Single Turbo - 400bhp - Sold

Rx8 231 - Run about - 231bhp - Sold

Subaru Impreza - Monster - 346BHP - Sold

200sx S13 - Budget Toy - 199.1bhp

Project Mini - 50% Done
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
cheers stevey

oh i forgot to pick that caliper carrier of you the other night only remembered when i got home DOH !
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
piston spray nozzle location
Posted Image
spray nozzles
Posted Image
block with ARP studs being installed
Posted Image
ARP main stud kit
Posted Image
re -ground crank .25 removed of main and big end bearing mating faces.
Posted Image
skimmed and re-bored block, (block had .1mm, or 4 thou skimmed off the head gasket mating face and was re-bored from 86 to 86.5mm).
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
no2 piston spray nozzle installed
Posted Image
oil scraper seal
Posted Image
oil scraper seal installed
Posted Image
main journal bearings being installed.
Posted Image
thrust bearing installed (one either side of the number three main bearing location).
Posted Image
modified main stud with a re-threading nut already on the shaft
Posted Image
re-ground crank laid into position.
Posted Image
main bearing caps installed and timing gear.
Posted Image
load spreader bar installed and torqued up.
Posted Image
the two modified studs closest to us. these studs have to be ground down as they foul on the cast part of the original sump they are located towards the aft section of the block
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
LegacyTurbo
No Avatar
y0
[ *  *  *  *  * ]
:D nice one mate :D
[GK-customfield]Lewis[customfield-GK]
Starlet GT 1.3 forged engine, tdo4 turbo @ 1.25bar = 252bhp = SOLD :(

EDIT: Charade GTxx 993cc three cylinder turbo, 173bhp @ 1.4bar (should hit 200bhp with a larger throttle body, removing stupid high lift cams and a bit more boost)
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
new wossner 86.5mm forged pistons
Posted Image

Posted Image
forge piston attachments
Posted Image

Posted Image

steel eagle con rods and the method we used to separet them, slacken the bolts and just tap on the bolt heads, whilst supporting like this and they slowly split apart.
Posted Image
gudgeon pins were a push fit with surclips at either end. lubed up with moly lube.
Posted Image
spot the difference, new steel rod on the left does not have a exit hole for the oil to escape out of but on the original con rod the hole was for a fine oil spray to the small end, which had no lubrication ports on the rod at the small end, with the forged pistons there have there own lubrication ports.
Posted Image
number one and four piston and rod assemblies installed and torqued up.
Posted Image
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
Stevey
No Avatar
Drift Slag
[ *  *  *  *  * ]
justbutts
Aug 26 2007, 10:10 AM
cheers stevey

oh i forgot to pick that caliper carrier of you the other night only remembered when i got home DOH !

Not a problem ill keep it in the boot untill we meet again :D
200sx S14A - Stage 3A - 350bhp - Sold

Rx7 FD3S - Single Turbo - 400bhp - Sold

Rx8 231 - Run about - 231bhp - Sold

Subaru Impreza - Monster - 346BHP - Sold

200sx S13 - Budget Toy - 199.1bhp

Project Mini - 50% Done
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
all forge pistons installed
Posted Image
Posted Image
splash guard installed
Posted Image
gasket sealer
Posted Image
rear crank case seal installed
Posted Image
yellow link on timing chain lines up with the timing mark on the crank sprocket
Posted Image
timing chain guide and chain tensioner guide installed, chain tensioner guide is on the right of picture as you look at it.
Posted Image
new oil pump rotors as old rotors had bits of bearing embedded into them.
Posted Image
oil pump cover and timing cover installed
Posted Image
water pump installed
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
Stevey
Aug 26 2007, 10:52 AM
justbutts
Aug 26 2007, 10:10 AM
cheers stevey

oh i forgot to pick that caliper carrier of you the other night only remembered when i got home DOH !

Not a problem ill keep it in the boot untill we meet again :D

cool matey gonna post up in sxoc bout thurs night meet you coming ?
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
oil pick up strainer installed
Posted Image
cast sump installed, where the flange section is towards the right hand side of the photo is where the two studs earlier where fouling against.
Posted Image
baffle plate installed
Posted Image
greddy winged baffled sump external
Posted Image
greddy sump internal notice baffle and hinged baffles to help stop oil starvartion under heavy cornering
Posted Image
greddy sump installed
Posted Image
inlet valve note spring with green paint is standard valve spring and the red dot are greddy uprated valve springs.
Posted Image
cylinder head with .1mm, 4thou skimmed off and with the inlet valve removed.
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
valve removal tools
Posted Image

Posted Image

Posted Image
inlet valve left and exhaust valve right
Posted Image
inlet and exhuast valve removed.
Posted Image
greddy uprated valve springs
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
cometic 1.6mm metal head gasket
Posted Image
cometic metal head gasket in position
Posted Image


Affectively i have lowered the compression ratio on this engine.

the standard gasket is 1.2mm, the new gasket is 1.6mm making a difference of .4mm betwwen the gaskets.

but due to having a total of .2mm skimmed off the mating faces, the gasket is effectively only now .2mm difference overall, so now it is affectively acting as a 1.4mm gasket.


cylinder head installed and chain kept in tension with mallet :rolleyes: not shown are the ARP head stud kit. whcih you can only install once the head is in position and not before, due to the angle the chain guide sticks out the top.

Posted Image

Posted Image
power steering pump bracket installed and chain now kept in tension by cable tie :D
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
alternator bracket installed
Posted Image
aircon pump and bracket installed
Posted Image

Posted Image
cylinder head with hydraulic lash adjusters and rocker are stoppers being installed
Posted Image
cams installed
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
oil filter housing plus cooling and heater matrix pipes installed
Posted Image
GT2871R turbo and tubular manifold installed
Posted Image

Posted Image
alternator belt installed
Posted Image
aircon pump belt installed
Posted Image
cas sensor and engine to radiator return pipe installed.
Posted Image
inlet manifold and suport brackets installed
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
new tomei 256 11.5mm lift inlet and exhaust cams
Posted Image
new tomei cams and greddy rocker arm stoppers installed, note splash guard on top of stoppers has to have the two corners closest to us trimmed off so it fits back into position
Posted Image
fidanza flywheel installed. note the metal gear box gasket plate has to go on before you install the flym wheel as the hole in the middle is to small to fit over the fly wheel
Posted Image
RPS street max clutch plate located in position
Posted Image
RPS street max 475ftlbs pressure plate installed.
Posted Image
new light weight alloy pulleys
Posted Image
new apex high flow turbo elbow.
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
new apex uprated engine and gear box mounts
Posted Image
new nismo 740cc injectors
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
engine bay prepped for engine installation
Posted Image
my ugly mug and engine before the swearing starts :popeye:
Posted Image

this will just slot straight in :wtf: yeah right !

(fellow sxoc chappie adam in, big fish, little fish, card board box mode).
Posted Image
finally afater hours of struggling the engine is in :yay:
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
my old rocker box cover before repaint.
Posted Image
my rocker box cover now after painting. big thank you to gerry and the guys at hard rock customs @ bournemouth airport :thumbsup:
Posted Image

Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
justbutts
No Avatar
Doesn't have a home to go to!
[ *  *  *  *  * ]
rocker box cover installed
Posted Image
my apex performance type 2 front mounted intercooler.
this intercooler has longer pipe runs, but the pipes use the exsisting cuts outs for the standard wing mounted intercooler so its really easy to fit.
Posted Image
Adams apex performance type 1 intercooler like most other after market front mount intercooler requires some front end modifications to chassis parts to get it to fit.
Posted Image
the biggest mod being the cutting of a 86mm hole into the battery tray for the cooled air pipe. (cut by my self :D )
Posted Image
my car on the left with type 2 intercooler and adams car on the right with type 1 intercooler
Posted Image
[GK-customfield]mark[customfield-GK]Horsham Developments stage 3a (GT2871r) 363bhp @ 1.4bar nissan 200sx s14a
Posted Image
Offline Profile Quote Post Goto Top
 
1 user reading this topic (1 Guest and 0 Anonymous)
Go to Next Page
« Previous Topic · Nissan: Projects & Modifications · Next Topic »
Add Reply

Free Domain Name Registration