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Underbody braces, turbos and more!

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 Post subject: Re: 1.0 rebuild
PostPosted: Mon Feb 22, 2010 6:28 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
I almost got my stuff together. This is what I have so far:

image_id: 18429

- clutch kit
- 1.3 flywheel
- head gasket kit
- crank seals (not in picture)
- +10 gear (on old cam)
- new 365/222 cam :D :D
- cleaned, shaved and ported head
- new SS valves
- new headbolts
- spark plugs
- piston rings
- underbody brace (should be easy to fit with engine out)
- 91 TBI
- oil and filters

I was planning to put it all together, but yesterday a friend of mine blew the head gasket of his GT. Because he needs his car and mine is only hobby, I'm going to fix his first. Mine is waiting for almost two months already, so another week won't hurt. Updates will follow ofcourse :)

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Thu Mar 11, 2010 3:48 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
Today I unhooked the engine, so it will come out quickly for the coming swap. Labeled and disconnected every connector, tapped the remaining fluids, unbolted the exhaust and took the axles out. I also took a close look at the crank seal, but couldn't see anything suspicious. Looked up from below and there I found the real problem. The oil filter's o-ring popped out :shock: . Filter is still (hand)tight, so I wonder what happened? Clogged passage and pressure buildup? I also noticed that the exhaust bolts came out easily, which is strange, because my other car had about the same mileage and age and I had to grind off the bolts of that. The gasket was pretty new also. I guess the car has had some more problems before. Anyway, engine is ready to come out, other one is slowly coming together, now I need an engine hoist. =)

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Wed Mar 17, 2010 11:51 am 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
I'm still gathering nice parts for the car and next week I'll have an engine hoist. The weather is pretty good now, so it might happen one of these days :D 8)

Some new parts:

image_id: 18536
I found these 14x6 BSA's on the internet, not too expensive. One of the best looking rims I know. They will be flat black with a gold pinstripe on the edge. These will do until I have my GTi wheels made pretty. Those will be blasted and powdercoated, with a polished edge.

image_id: 18538
New lugnuts. Stock ones won't fit the holes on the BSA's.

image_id: 18537
Car will be 35mm lower with these nice Apex springs 8)

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Tue Mar 30, 2010 3:24 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
Got an engine hoist and took the old engine out this afternoon.

image_id: 18586

It was a simple job to do, didn't even have to remove the hood. I also found out that my old intake which I wanted to use has a different TPS, and won't fit without switching throttle shafts. Don't have time to do that properly, since MOT is next week. Too bad for now. Now the engine is out I tried fitting my underbody brace. Using a comealong, I managed to get it over the studs, but it turns out that a '91 brace won't fit without enlarging the holes to 16 mm. That's for tomorrow.

I've also put the head back together after lapping the valves for the second time. I also filled the oil passages until oil was pouring out everywhere:

image_id: 18587

image_id: 18588

image_id: 18589

I leak tested by blowing smoke through the ports and so far the valves are airtight. Tomorrow I'll do a wet test though =). The valves have almost no play in their guides and the lifters move smoothly. Can't wait to get it running again :D.

Mailman brought a present today. Four Nankang AS-1's, size 165/55-14:

image_id: 18590

I hope to finish painting the wheels soon, so I can use them after lowering and an alignment :D That's it for now, there will be more tormorrow 8)

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Wed Mar 31, 2010 2:14 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
Did the brace today, had to drill the holes to 16 mm first, otherwise it wouldn't fit my current car, since the brace was intended to go on my '91. After drilling and applying a bit of violence, it fit perfectly:

image_id: 18592 image_id: 18593 image_id: 18594

Now all left to do is fitting lowering springs, engine and wheels and tyres :D 8)

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Profile  
 
 Post subject: Re: 1.0 rebuild
PostPosted: Wed Apr 07, 2010 7:55 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
Lots of progress the past two days :D Here are some pictures:

image_id: 18609 image_id: 18610 image_id: 18611

image_id: 18613 image_id: 18614 image_id: 18615

image_id: 18616 image_id: 18617 image_id: 18618

Few things left to do before I fire her up tomorrow:

- oil and new filter
- coolant
- gear oil
- camshaft and distributor
- valve cover
- re-adjust TPS
- air filter
- header and cat
- belts
- new battery
- front and rear springs
- axles
- check for fluid leaks
- check for oil pressure
- put plugs in
- turn the key

I like the last one, because then I'll have my own car again, I kind of missed her =) . I'm also tired of biking around and my gf's GTi is bad for my wallet and driver's license if I keep driving that thing. Ever since the 3tech cams are in there, I like to floor it, just for the sound :lol: 8)

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Fri Apr 09, 2010 3:30 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
It runs!!! Almost like new :D :D :D

Yesterday I filled up the radiator and burped the cooling system. Pinched every hose I could find, last thing I did that day. When I got outside this morning and found a small spot of coolant on the ground under the oil pan. Turned out to be the intake manifold gasket, I fastened the bolts and nuts in the wrong order. As in no order at all. Took it off and wiped it al clean and put it back together, bolts and nuts from one side to the other. Leak is gone. Filled the engine up with oil, put the cam in, put the rest back together, valve cover off, pulled the fuel pump relay and the plugs. I let the lady take place behind the (absent) wheel and crank it until there was oil in the head. I put my fingers in the plug holes and there was lots of compression :D . Put the plugs and wires in, put the valve cover back on, stock air filter for now (forgot to oil my K&N) turned the key and VROOM!! Idle was at 1500 rpm, lifters were rattling like crazy, but throttle response was already great. I cleared up my tools, put a new QSP steering wheel in, and went for a drive. The first meters, I immediately noticed the difference. Definitely faster :D When I got on the main road, I went through the gears and I really love it!! 3tech's 222/365 cam rocks! At traffic lights she idled at just under 1000, lumpy but stable. When pulling hard through all gears, the intake and exhaust sound much darker than before. Simply awesome 8) I'll post some pictures tomorrow :D :D

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Sun Apr 11, 2010 9:04 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
Some pics:

image_id: 18621 image_id: 18622 image_id: 18623

Engine runs great so far. I didn't push it all the way yet, but with the cam I regained some top end power and bottom end got much better. I still need a bigger throttle. Also have a small oil leak at the valve cover. I kind of figured it would leak, since the rubber gasket did fit, but I had some doubts about the thing.
Only the front end is lowered for now, I like the way it looks and handles. Have to get it realigned, because of the brace and the lowering. It's a bit off, pulls to the left.

The only things left to do are the wheels and tires and getting the dent fixed. I'm very pleased with the results so far :D :D 8) :twisted:

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Wed Apr 14, 2010 12:02 pm 
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Joined: Fri Jan 01, 2010 8:49 pm
Posts: 95
Location: Alabama
How did you adjust the TPS? Looking real good!


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 Post subject: Re: 1.0 rebuild
PostPosted: Wed Apr 14, 2010 12:21 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
Thanks! :D I adjusted the TPS to factory specs. Runs great. However, it failed emissions at idle. Far too rich. I just put the stock cam in and one or two lifters won't bleed enough to let the valves shut on cylinder 2, so it only runs on 1&3 now. I hope they will bleed over the night, so I won't have to open her up one extra time.

I finally finished painting the wheels two days ago and today I had the car realigned and put the wheels under, with new tires. They are Nankang's AS-1, size 165/55-14. I think she looks pretty cool with black wheels:

image_id: 18641 image_id: 18642 image_id: 18643

Edit: I tried starting her again and she runs on all three now. Didn't take too much time for the lifters to bleed.

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Tue Apr 27, 2010 5:28 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
I've covered just over 1000km's since first startup and all I can say is that I'm a happy man. Sounds awesome, pulls great, corners well. Past emissions with the stock cam. When the car got checked, I had a chance to get a good look at the underside of the car, together with the shop owner and I was very pleased to see there is absolutely no rust. No leaks, no torn boots, everything was just fine. The guy said to me: "I hate these kind of cars, can't make any money out of them." :mrgreen: I couldn't be happier :D :D

Replaced the oil today, with filter ofcourse. The oil that came out had a nice silver shine, so I'm glad it's out. While I was under the car anyway, I removed the cat and put a nice 2" ss pipe in place. My gf had that made for her old 1.3, and I compared it to my cat and thought it should fit and it actually did =) . It's not perfectly lined up with the rubbers, but it hangs and doesn't touch anything. I got a bonus with that pipe, it has the bend it needs to clear the swaybar, so I put that under too. I had a 22mm bar lying around, with a nice gold Hammerite finish. I also refurbished the cigarette lighter :drunk: Here's some pics:

image_id: 18734 image_id: 18735 image_id: 18736

image_id: 18737 image_id: 18738

Handling improved significantly and the exhaust growl is even louder than before :twisted: . Top end feels better, but I haven't driven it alone yet. Last weekend I made some 0-100 runs, with a best of 13.16s. :D 8) I got a feeling I can get under 13 without cat, maybe top speed will be higher too. I definitely need a bigger throttle, but for now it's just about the way I wanted my old one to be :D . This week I'll add some gauges. The lighter feels nice and smooth and is very shiny.

I'm kind of glad the engine broke down :huh: , otherwise, I wouldn't have been this far right now. Now I'm looking into a simple junkyard turbo setup to mess around with on this engine this summer. Should be fun.

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Tue Apr 27, 2010 6:33 pm 
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Sad but True...

Joined: Fri Jul 27, 2007 8:20 pm
Posts: 2973
Location: Saskatchewan
hmmm

I have a complete t3 system that would bolt right up to that beast. much improved intake manifold and throttle body, aswell as a turbo manifold, turbo, injectors, ecu, harness, brackets, bolts, every little thing that you would need. pm me if interested. everything is in great shape and I warn you the price may reflect that a little

_________________
1991 Swift GT Build G10 +25 psi + other goodies
1996 Metro Build QR25de swap, still undecided where to take it
the lolcar family


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 Post subject: Re: 1.0 rebuild
PostPosted: Mon May 03, 2010 6:41 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
I want to keep it cheap and simple for now. Get a used turbo, make my own exhaust manifold, pressure hat and downpipe to practice welding =) , cts mod for extra gas. Save the money for a proper rebuild of the busted engine.

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Mon May 03, 2010 7:57 pm 
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Joined: Sun Aug 31, 2008 12:47 pm
Posts: 640
Location: Olympia, WA
Peenutzz wrote:
Thanks for the tip, I almost forgot. Just compared the old with the new one and the holes match up perfectly. Nipparts makes pretty good stuff. Here's a pic of the new one, with the old one underneath it:

image_id: 18171


Aww, dang it!! Wish I hadn't been "asleep at the keyboard" over the winter...

You're probably OK, but take a close look at the impressions left on my old head gasket in this picture:
Image

In this picture, the head and gasket are both upside down. The top surface here was actually laying face down on the top of the block. The circular impressions left by the block drain back holes are clearly visible. The area on the left side where the actual opening overlaps the impression represents the actual opening you have available for oil to drain through. The rest of that opening sits on the top surface of the block. On the right side, the drain back opening in the head appears to match the size of the opening in the block, but as you can see, the hole through the gasket is tiny by comparison.

Most motors... no big deal, but in my case, the small holes caused oil to back up on the head and it ended up blowing a huge smoke screen out my tailpipe while tooling down the freeway at something like 58 (or was it 62?) MPH.


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 Post subject: Re: 1.0 rebuild
PostPosted: Sat May 15, 2010 5:33 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
G-Whiz wrote:
In this picture, the head and gasket are both upside down. The top surface here was actually laying face down on the top of the block. The circular impressions left by the block drain back holes are clearly visible. The area on the left side where the actual opening overlaps the impression represents the actual opening you have available for oil to drain through. The rest of that opening sits on the top surface of the block. On the right side, the drain back opening in the head appears to match the size of the opening in the block, but as you can see, the hole through the gasket is tiny by comparison.

Most motors... no big deal, but in my case, the small holes caused oil to back up on the head and it ended up blowing a huge smoke screen out my tailpipe while tooling down the freeway at something like 58 (or was it 62?) MPH.


That looks way off :shock: I can imagine it would smoke alot. Like you said, mine is fine. No smoke up to 145kph (90mph). Can't go much faster :lol:

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Wed Jan 16, 2013 12:29 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
It's been awhile since i've been here, and I felt like an update on the status of my Swift. Didn't do much to it the past 3 years, except for the usual maintenance. I've driven over 45k kilometers since the car was rebuilt and the only problem I've encountered so far was the cam seal popping out a year ago. I didn't even notice for a day, until I saw a big greasy, dripping spot next to the headlight.

Now I'm looking into throttle bodies and how I can get them to work properly on my 1.0, before I go on with the turbo I have lying around. I know I will lose some bottom end torque, but I don't care =)

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Sun Aug 04, 2013 12:01 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
Update:

A while ago, my oil pressure light started lighting up. Hot engine and only at idle rpm's. I found some possibilities on the forum, like the oil strainer, or a faulty pressure sender, or one or more cam journals that could be out of spec. Because of the insanely hot weather (30-35C or 86-95F) I didn't feel like going out there and check them out. Instead, I got my CB500 out from under the dust and used that for transportation. Today, the weather was bearable, but still too hot for lying under the car, so I got hold of some plastigage and I measured the cam journals, turns out #1 seems to be the problem, I measured a clearance of .076+ mm (off the scale), while the other two were around .03 mm, well within spec. I double checked and now I'm looking for another head. Again, I will port it, polish the bowls, add stainless valves, etcetera. Since I got the time now (MOT was three months ago) I also plan to fit my old tbi, because of the bigger throttle. Updates will follow :)

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Sat Aug 10, 2013 7:44 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
I sent suprf1y a pm regarding the issue and he believes that the journal clearance isn't necessarily the problem. I ordered a pressure gauge which should arrive this monday and in the mean time I checked a few things.

- new pressure sender, no good
- oil pickup tube checked, no problem there, replaced it anyway, still no good
- oil change, no good either
- checked for leaks, none other found than in the usual 'wet spots'

I couldn't get the pressure relief valve out, but it moves up and down freely. Should I check it again?

edit:
Today I noticed that since I checked the pressure relief valve it takes a few rpm's less for the light to switch off. First it took 1000 rpm, now it's about 900, idle rpm is set at +/-850. My guess for now is that there is some sludge or debris behind the valve which I compressed while moving the valve up and down, so the valve closes a little further than before. Any other ideas?

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Tue Aug 20, 2013 8:32 am 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
I hooked up a pressure tester to the main gallery today, cold start gave me a reading of 2 bar/28psi , dropping to 1 bar/14psi during warmup. Definitely a problem here, I'm about to check the relief valve again. If that doesn't solve it, I'll replace the oil pump, I got a spare one. I really hope it's just a minor thing, because I planned to go to France next month and I'd really like to take my own car.

edit:
After cleaning the relief valve, readings are pretty much the same. Max pressure I get is 2.4bar/34psi, idle is down to 0.8bar/12psi.

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Mon Aug 26, 2013 4:35 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
I replaced the oil pump with one that's 50k km's younger, pressure got only slightly higher, but I got no more oil light lighting up. I think I'm good for now.

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Profile  
 
 Post subject: Re: 1.0 rebuild
PostPosted: Fri Sep 27, 2013 5:09 pm 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
Well I'll be d@mned. I think I have just really solved everything by replacing the head gasket :D :D I have had some minor issues, but I just didn't see the connection until four weeks ago. I started the car and there it was: A white cloud in the mirror.

Three years ago, not long after the rebuild, I noticed that I lost some coolant somehow, not much not even a 100cc's, but it was gone. There was no white smoke coming out the exhaust, so I just topped it up, thinking I simply didn't burp the system properly. Wrong! It probably just smoked a little at startup, but not enough to notice, I don't really know because I haven't checked. Fact is, it didn't burn coolant while running, because combustion pressure kept the coolant out. At that time the leak was probably very small and only into the cooling system.
The next few years the car ran great, passed emissions every year up to now and the only major problem I encountered was the cam seal popping out. I blamed it on the freezing weather, put a new seal in, and went on with my life. Wrong again. The leak was getting bigger and combustion was pressurizing the crankcase now. Not much, but enough to push out a two year old seal. I put some liquid gasket on the new one, so it would stick better and it did and still does.
Every once in a while, the car would start a bit harder than usual. It had trouble getting through the compression. Radio and lights went out, but it started right up once it past the 'hard spot'. Battery was getting bad, so I decided to wait until it almost died and then replace it. Another wrong. Leak was getting bigger again and coolant seeped into one of the cylinders. I didn't think of that because I didn't look for white smoke and it didn't happen very often. Battery still works.
Then there is the catch tank. I had to drain it more often than a friend of mine had to with his GTi, but I drive a lot of short distances, so I blamed that. This is getting boring :P Coolant leaks into crankcase. It still wasn't very much, so I didn't look any further.
I'm starting to believe the oil pressure problem had something to do with it too.

If I had just payed some more attention I could have figured it out much sooner. Car ran great all the time, coolant loss was very little and the other symptoms were a bit vague so I simply didn't bother :oops: :oops:

Last weekend I took off the head, and when loosening the head bolts it immediately became clear that something went wrong when I put it together the first time. One bolt came out easier than the rest and that was exactly the place where the leak was. I had the head cleaned and shaved 0,5mm, put it back together with new gaskets and everything, replaced some old hoses on the intake and put the head back on the cleaned engine after work on wednesday afternoon. This time I torqued the bolts in steps of 15Nm, with a quarter turn back after every step, some trick I found in several places on the internet. The idea is to precompress the gasket, recommended for graphite gaskets. Fired right up and went for a test drive and I was surprised. Is this the same car? It feels even more powerful than before, idles better, awesome throttle response and somehow, the sound got so much better, darker, more agressive, I just can't believe it :D :D

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Post subject: Re: 1.0 rebuild
PostPosted: Wed Dec 18, 2013 3:18 am 
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Joined: Sat May 18, 2013 12:48 am
Posts: 170
Location: San Diego CA
do you have all the pics, i love pictures! the ones here are gone!


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 Post subject: Re: 1.0 rebuild
PostPosted: Thu Jan 23, 2014 10:48 am 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
Sorry, it's been a while. I'll upload new ones as soon as I get the the chance. Probably later tonight :)

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


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 Profile  
 
 Post subject: Re: 1.0 rebuild
PostPosted: Sat Feb 15, 2014 1:57 am 
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Joined: Sat May 18, 2013 12:48 am
Posts: 170
Location: San Diego CA
bump =)


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 Post subject: Re: 1.0 rebuild
PostPosted: Mon Feb 17, 2014 10:21 am 
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Joined: Mon Jan 17, 2005 5:21 pm
Posts: 353
Location: Oss, the Netherlands
Sorry, my whole album is empty, and uploading the pics again and editing all the posts is a lot of work. If you want, I can attach some pics to this post, what would you like to see?

_________________
'95 Swift 1.0:

- 0,5mm oversized pistons
- mildly ported head, 1,7mm taken off
- ss exhaust valves
- 222/365 3tech cam
- +10 gear
- K&N air filter
- TBI bridge removed
- 40mm throttle and intake manifold
- srd underdrive pulley
- AASCO 3kg flywheel with GTi clutch
- GTi catback
- deleted cat, now 2" ss pipe
- 14x6J ET45 BSA Racing
- Nankang AS-1 165/55-14
- 35mm lower Apex front and rear springs
- GTi sway bar
- Turbinetech underbody brace
- Ultra Racing upper strut bar

0-100kph: unknown seconds


Top
 Profile  
 
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