DCK Project started

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ROVER-25X
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Re: DCK Project started

#16 Post by ROVER-25X » Thu May 12, 2016 10:56 pm

Saw this on Tuesday, going to be a cracking car mechanically. :clapping
ROVER-25X (2001 1.4 ROVER 25)
ROVER Cabriolet (1997 1.6 K-Series)
ROVER 25XD (2004 2.0TD ROVER 25)
ASTRA TwinTop 1.9CDTi

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1234dist
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Re: DCK Project started

#17 Post by 1234dist » Fri May 13, 2016 7:43 am

All brakes now complete. Which included drilling and tapping the rear hubs after both sides had previous snapped off bolts in the disc placement screw holes.

All wiring and other nasties that shouldn't be there removed from the engine compartment.

PS bottles fitted.
expansion bottle fitted.

Gearbox refurbished waiting clutch release arm.

Was a busy day yesterday.

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220 Coupe turbo K785OAT (issues :glare )
Rover Sport 220GTI m-series K56AEP
218 VVC Cabriolet R220OVR
220 GTI M-series J777RAL
75 2.0 CDT P80CJM
620 SLI P267LOM HONDA
420 GSI Turbo L191CVP

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ROVER-25X
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Location: 1hr 10m from 1234dist
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Re: DCK Project started

#18 Post by ROVER-25X » Fri May 13, 2016 10:26 pm

Image
ROVER-25X (2001 1.4 ROVER 25)
ROVER Cabriolet (1997 1.6 K-Series)
ROVER 25XD (2004 2.0TD ROVER 25)
ASTRA TwinTop 1.9CDTi

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Johnny 216GSi
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Re: DCK Project started

#19 Post by Johnny 216GSi » Sat May 14, 2016 12:17 am

Another manifold swap as well...

Wouldn't mind seeing a picture of what you replace these with, re. coating/refurb etc.
Rover 216GSi K reg. Flame Red over Tempest Grey

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1234dist
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Re: DCK Project started

#20 Post by 1234dist » Sat May 14, 2016 7:49 am

Will only be using stock parts, nothing fancy :mope
220 Coupe turbo K785OAT (issues :glare )
Rover Sport 220GTI m-series K56AEP
218 VVC Cabriolet R220OVR
220 GTI M-series J777RAL
75 2.0 CDT P80CJM
620 SLI P267LOM HONDA
420 GSI Turbo L191CVP

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1234dist
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Posts: 5612
Joined: Fri Aug 26, 2011 9:08 pm
Location: Chapel of Dist, Manchester
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Re: DCK Project started

#21 Post by 1234dist » Thu May 19, 2016 3:06 pm

Well update time again.

Time to turn my attentions to the mountain of oil in the corner. The engine.
It looked ok, probably could have been dropped in as it was, but you know me. I have to be sure everythings right and a good job i did.

Some of the bolts were only finger tight and others, maining the one that holds the alternator and ps to the block where loose.

Either way, gaskets needed replacing, oil removed and a general spruce up and check of all the components.

Clutch had seen better days, a long time ago
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Off with the alternator and ps and water pump housing
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mmm not so shiny
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Cam seals look past their best based on the sheer quantity of oil behind the broken cam covers
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Thermostat housing in primer, ready for silver
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same with the water pump housing, old pump still in there for now.
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New clutch release arm, counter weight and release bearing claw all greased up, then cleaned off
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New o-ring fitted to the water pump housing, old one squished.
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reassembly begins
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Sensors replaced and greased
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New clutch fitted
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Now we are just waiting on shirly to drop me some new gaskets and i can reassemble and get ready to fit the gearbox to the engine and get it all back in the car.

:cool
220 Coupe turbo K785OAT (issues :glare )
Rover Sport 220GTI m-series K56AEP
218 VVC Cabriolet R220OVR
220 GTI M-series J777RAL
75 2.0 CDT P80CJM
620 SLI P267LOM HONDA
420 GSI Turbo L191CVP

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ROVER-25X
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Posts: 1242
Joined: Wed Feb 17, 2016 1:17 pm
Location: 1hr 10m from 1234dist
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Re: DCK Project started

#22 Post by ROVER-25X » Thu May 19, 2016 9:39 pm

Image
ROVER-25X (2001 1.4 ROVER 25)
ROVER Cabriolet (1997 1.6 K-Series)
ROVER 25XD (2004 2.0TD ROVER 25)
ASTRA TwinTop 1.9CDTi

User avatar
1234dist
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Posts: 5612
Joined: Fri Aug 26, 2011 9:08 pm
Location: Chapel of Dist, Manchester
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Re: DCK Project started

#23 Post by 1234dist » Sun May 22, 2016 3:41 pm

Time to put the engine back together.

Cams off and new seals fitted
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Followed by new cam cover gaskets
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Covers fitted, new plugs, cleaned ht Leads, new dizzy cap and rotor arm and both thermostat gaskets and thermostat replaced.
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Lower inlet gasket
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Upper inlet fitted
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Time to drill and tap the two snapped bolts in the bonnet.
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And another nasty surprise, as we were searching the bolt tin for replacement bolts for the mounts, this one came off. and its really smooth meaning its been moving around freely for some time.
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And finally the nasty water pump, will do a completed pic later as the rain has started
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220 Coupe turbo K785OAT (issues :glare )
Rover Sport 220GTI m-series K56AEP
218 VVC Cabriolet R220OVR
220 GTI M-series J777RAL
75 2.0 CDT P80CJM
620 SLI P267LOM HONDA
420 GSI Turbo L191CVP

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ROVER-25X
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Posts: 1242
Joined: Wed Feb 17, 2016 1:17 pm
Location: 1hr 10m from 1234dist
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Re: DCK Project started

#24 Post by ROVER-25X » Sun May 22, 2016 4:10 pm

That pump is as bad as mine ! :blink
ROVER-25X (2001 1.4 ROVER 25)
ROVER Cabriolet (1997 1.6 K-Series)
ROVER 25XD (2004 2.0TD ROVER 25)
ASTRA TwinTop 1.9CDTi

User avatar
1234dist
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Posts: 5612
Joined: Fri Aug 26, 2011 9:08 pm
Location: Chapel of Dist, Manchester
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Re: DCK Project started

#25 Post by 1234dist » Sun Jun 05, 2016 3:34 pm

So today was slightly hotter than we planned for.....This hot

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But, progress was required so sun tan cream on and engine off we go with attaching the gearbox and dropping the engine into the engine bay.

Cam covers and mount borrowed from one of my other cars so we could time up and fit the belts.
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Genuine oil seals replaced on the gearbox after a little refurb of the second gearbox (long story).
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One complete engine ready to fit.
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and she's in, just a couple more mounts and we're good.
Image
220 Coupe turbo K785OAT (issues :glare )
Rover Sport 220GTI m-series K56AEP
218 VVC Cabriolet R220OVR
220 GTI M-series J777RAL
75 2.0 CDT P80CJM
620 SLI P267LOM HONDA
420 GSI Turbo L191CVP

User avatar
ROVER-25X
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Posts: 1242
Joined: Wed Feb 17, 2016 1:17 pm
Location: 1hr 10m from 1234dist
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Re: DCK Project started

#26 Post by ROVER-25X » Sun Jun 05, 2016 8:11 pm

Couldn't resist, took me an hour to make but just though of this when I saw your progress *laughs*. :laughing2


LINK: https://www.youtube.com/watch?v=ujMgON0 ... e=youtu.be
ROVER-25X (2001 1.4 ROVER 25)
ROVER Cabriolet (1997 1.6 K-Series)
ROVER 25XD (2004 2.0TD ROVER 25)
ASTRA TwinTop 1.9CDTi

User avatar
1234dist
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Posts: 5612
Joined: Fri Aug 26, 2011 9:08 pm
Location: Chapel of Dist, Manchester
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Re: DCK Project started

#27 Post by 1234dist » Sun Jun 05, 2016 8:28 pm

:laughing2 Exactly what rick said.

Still very bolt deficient and a rear engine mount but power steering is now plugged in too
220 Coupe turbo K785OAT (issues :glare )
Rover Sport 220GTI m-series K56AEP
218 VVC Cabriolet R220OVR
220 GTI M-series J777RAL
75 2.0 CDT P80CJM
620 SLI P267LOM HONDA
420 GSI Turbo L191CVP

User avatar
Johnny 216GSi
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Posts: 2039
Joined: Wed Nov 19, 2014 10:17 pm
Location: Birmingham - the home of Rover!

Re: DCK Project started

#28 Post by Johnny 216GSi » Mon Jun 06, 2016 8:16 pm

So when does it get fired up? I'm probably as excited as Rick is in knowing how it's all gone. Some solid engineering work there. How to bring a T series back from the brink in half a dozen photos. Looks easy... :laughing2

It's a day after your last post, so maybe it's guzzled its first few cup fulls of Asda's finest already...
Rover 216GSi K reg. Flame Red over Tempest Grey

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1234dist
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Re: DCK Project started

#29 Post by 1234dist » Mon Jun 06, 2016 8:31 pm

a little premature yet, remember this car had nothing!

So at the moment i have to finish off the ps pipes, engine loom, fuel lines, fuse box, oil feed pipes, turbo, exhaust manifold, drive shafts, front control arms.

So, a bit to go yet :slapme
220 Coupe turbo K785OAT (issues :glare )
Rover Sport 220GTI m-series K56AEP
218 VVC Cabriolet R220OVR
220 GTI M-series J777RAL
75 2.0 CDT P80CJM
620 SLI P267LOM HONDA
420 GSI Turbo L191CVP

User avatar
ROVER-25X
Club Member
Posts: 1242
Joined: Wed Feb 17, 2016 1:17 pm
Location: 1hr 10m from 1234dist
Contact:

Re: DCK Project started

#30 Post by ROVER-25X » Thu Jun 09, 2016 1:01 am

Get cracking. :D
ROVER-25X (2001 1.4 ROVER 25)
ROVER Cabriolet (1997 1.6 K-Series)
ROVER 25XD (2004 2.0TD ROVER 25)
ASTRA TwinTop 1.9CDTi

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