What you put in, you'll get back ten fold
Having problems logging in? Please clear your cache and remove the MazdaMenders related cookie from your browser.
If you need assistance doing this, don't hesitate to contact us on FaceBook or email forum-admin@mazdamenders.net stating the browser you use.

Regards
Admin

Engine swap with photo's mk1 1.6

Car sales, services, and Mx/Roadster enthusiast, owned by one of the admin team, Nedski aka Neil stokes, fellow owners always welcome for a brew and a jammie dodger.
User avatar
nedski
Serial Poster
Posts: 732
Joined: Fri Jun 01, 2012 11:17 pm
Location: North Kelsey, Market Rasen
Contact:

Engine swap with photo's mk1 1.6

Postby nedski » Fri Nov 07, 2014 12:31 pm

This weeks project.
Swapping out a sick 1.6 engine for another.

The old engine suffered a lack of oil with a split turbo return pipe, and it sadly became a bit poorly. Cheapest solution was to swap it for another.
The new engine was the right price but unfortunately a short nose engine that was very oily. This meant the crank pulley had to come off to replace the oil seal. Special attention has to be given to the short nose engine as the front pulley is it's week spot. Also the tightening torque for the front crank bolt is lower than Haynes manuals says. It should be set at 80-87lb/ft. So while I was at it, I changed all the oil seals and gave it a quick clean.
Crossing fingers at start up because you never know with used engines. Sweet happy days :handgestures-thumbup:

So this will be a long picture thread of the work.

The start ! New engine sat on the cradle and the old lump about to be taken out.
Image

This is an older pic of the engine that's coming out with it's turbo and pipes etc.
Image

I find it easier to remove the inlet manifold completely. this gives better access to the starter motor. The turbo has been taken off too.
Image

Engine out. That's the easy bit done. You will also need a jack under the gearbox to lift it a little while clearing the engine mounts from the subframe.
Image

Engine to go in. Note the crank pulley has 4 slots (and a leaf by looks of it lol) this is the short nose engine. the long nose has 8 slots.
Image

The old engine.
Image

Sorry missing a few photo's. The new engine had had a wash in brake cleaner etc. I had decided to re new all it's oil seals and so the front crank pulley had to come off. Normally they fall off and that's their problem coming loose. Not this one, I had to fight it off as the pulley was well rusted on. I needed a lot of heat to get it to move. Sh#t or bust as they say. Anyway it's off but damaged so off to order a new one.
Image

The engine was stripped bare. Oil pump off, manifolds, water pump, sump, rocker cover, clutch, flywheel etc.
Then a bit more cleaning and painting.
Image

Image

Image

Then it was put to one side for paint to dry and parts to arrive.
Image

The old engine had a new water pump and a modified sump for an oil return from the turbo. This needed pulling off too.
Image

All the parts taken from the old engine waiting to go on the new one.
Image

Parts have arrived. £230 for those seals at a discounted price too. Double the engine price just for seals but they are oil genuine Mazda parts that won't leak hopefully. I've used none genuine before and had to do the job twice!
Image

So rebuild time..

Rear crank oil seal as it came off. Needs a clean!
Image

Image

Image

Image

Oil seal is on so flywheel can go on. Spot the mistake.
Image

The front of the engine is cleaned up ready.
Image

The all important crank pulley Key way is spot on.
Image

A check of a Big end bearing and a Main bearing. perfect
Image

Missed a pic of the oil pump going on. The engine is upside down ready to accept the sump.
Image

and the Sump baffle plate and oil pick up pipe.
Image

The brass fitting is threaded into the sump with the chemical metal is back up. Turbo oil return.
Image

Water pump ready.
Image

Image

on the left short nose oil seal. right is long nose oil seal. You cannot swap oil pumps.
Image

Image

Belt and braces for the short nose crank pulley. This is quality bearing fit to secure the pulley. The pulley is new and the bolt is new, as they are a stretch bolt to be used only once. the bolt also has thread lock applied.
Image

Image

Image

Image

New cam shaft oil seals.
Image

Image

Image

Cam belt fitted
Image

Image

Here is the mistake from earlier. No biggy but the back plate needs to be behind the flywheel.
Image

clutch aligned and going on.
Image

Image

If you need a turbo oil feed then this is it. The rear one in the pic
Image

Here we go.
Image

Image

Starter motor on before the manifold. Also easy to get at the bell housing bolts to bolt the engine in.
Image

Image

Image

See the braided hose for the turbo oil feed.
Image

Image

Image
One day the engine bay will get a clean too.

All done and runs a dream. Happy days. :handgestures-thumbup:
Mk1 1.6 Turbo. Gaz shocks. Tr Lane roll bar.
Garage Owner, Lincolshire
Helper to the Scunny track day crew and North Linc's Track Day Club.
www.stokesofkelsey.co.uk
The Captain
Turbo Charged
Posts: 2383
Joined: Wed Dec 07, 2011 8:53 pm

Re: Engine swap with photo's mk1 1.6

Postby The Captain » Fri Nov 07, 2014 12:38 pm

Nice one.

Return to ‚ÄúStokes of kelsey‚ÄĚ

Who is online

Users browsing this forum: No registered users and 1 guest