TB and top end refresh project
#46
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Thanks. I'm sure I'm forgetting thing too, but I have have been collecting parts for two or three years so I have a pretty good stash
some stuff I forgot I even had.
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#47
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Small ting today.
Insulated the fuel rails. Found some Pipe insulation material for solar installations, good up to 150C.
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0784.jpg)
Rebuilt the tensioner.
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0790.jpg)
Insulated the fuel rails. Found some Pipe insulation material for solar installations, good up to 150C.
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0784.jpg)
Rebuilt the tensioner.
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0790.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0791.jpg)
#48
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Replaced the freeze plug. Old one looks nasty but it isn't rusted on the inside, that's old sealant.
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0793.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0797.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0799.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0802.jpg)
Replaced the cam seals and the plastic oil block off thingies with new pins.
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0804.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0793.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0797.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0799.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0802.jpg)
Replaced the cam seals and the plastic oil block off thingies with new pins.
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0804.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0812.jpg)
#49
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Finally some new progress to report. I was somewhat stuck in the "need to renew that part too"-mode. Was ordering more and more until I said enough. Put this thing back together.
Soooo
After changing out all the the charcoal canister lines and vacuum actuator
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0867.jpg)
I installed new tensioner pads
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0853.jpg)
and new knock sensors
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0873.jpg)
I put the cam covers back on
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0880.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0887.jpg)
then the coolant bridge with an extra paper gasket
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0883.jpg)
then test fitted the intake
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0893.jpg)
and bolted it down with spacers (man! that's a lot of hoses, lines and wires to route correctly and tighten down!)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0914.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0915.jpg)
now, test fitting the fuel rails and new injectors
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0924.jpg)
What do you think? Too much black?
Soooo
After changing out all the the charcoal canister lines and vacuum actuator
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0867.jpg)
I installed new tensioner pads
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0853.jpg)
and new knock sensors
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0873.jpg)
I put the cam covers back on
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0880.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0887.jpg)
then the coolant bridge with an extra paper gasket
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0883.jpg)
then test fitted the intake
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0893.jpg)
and bolted it down with spacers (man! that's a lot of hoses, lines and wires to route correctly and tighten down!)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0914.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0915.jpg)
now, test fitting the fuel rails and new injectors
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0924.jpg)
What do you think? Too much black?
![ducking](https://rennlist.com/forums/graemlins/icon107.gif)
#51
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It's hard to see on my iPhone, did you add the aluminum spacers between the cam cover bolts, and conical washer?
Also you will need to pull the vacuum hoses, and throttle linkage off to be able to install fuel rails.
Last point, you will need to remove one of the water bridge bolts and remove the powdercoating under it to ensure the bridge is properly grounded, if it isn't your temp II will send a false signal to the brain and the car will not run right.
Confirm ohm test from each pin of temp II to temp II body, the chassis ground. There should be zero difference.
Also you will need to pull the vacuum hoses, and throttle linkage off to be able to install fuel rails.
Last point, you will need to remove one of the water bridge bolts and remove the powdercoating under it to ensure the bridge is properly grounded, if it isn't your temp II will send a false signal to the brain and the car will not run right.
Confirm ohm test from each pin of temp II to temp II body, the chassis ground. There should be zero difference.
#52
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Thanks! ![Cheers](https://rennlist.com/forums/images/smilies/beerchug.gif)
Colin, check, check and check. Did all that ![thumbup](https://rennlist.com/forums/graemlins/thumbup.gif)
Just tested the temp II sensor, got 4490 Ohm between the pins, 2240 Ohm between pin and ground, and 2230 Ohm between other pin and ground. This sensor is three years old.
Temp I though is as old as the car, but the temp gauge works normally. Tested it anyhow and got readings I didn't expect. I got 624 Ohm between the pins, and infinite resistance between each pin and ground.
Installed fuel rails and hooked up the engine harness.
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0926.jpg)
![Cheers](https://rennlist.com/forums/images/smilies/beerchug.gif)
It's hard to see on my iPhone, did you add the aluminum spacers between the cam cover bolts, and conical washer?
Also you will need to pull the vacuum hoses, and throttle linkage off to be able to install fuel rails.
Last point, you will need to remove one of the water bridge bolts and remove the powdercoating under it to ensure the bridge is properly grounded, if it isn't your temp II will send a false signal to the brain and the car will not run right.
Confirm ohm test from each pin of temp II to temp II body, the chassis ground. There should be zero difference.
Also you will need to pull the vacuum hoses, and throttle linkage off to be able to install fuel rails.
Last point, you will need to remove one of the water bridge bolts and remove the powdercoating under it to ensure the bridge is properly grounded, if it isn't your temp II will send a false signal to the brain and the car will not run right.
Confirm ohm test from each pin of temp II to temp II body, the chassis ground. There should be zero difference.
![thumbup](https://rennlist.com/forums/graemlins/thumbup.gif)
Just tested the temp II sensor, got 4490 Ohm between the pins, 2240 Ohm between pin and ground, and 2230 Ohm between other pin and ground. This sensor is three years old.
Temp I though is as old as the car, but the temp gauge works normally. Tested it anyhow and got readings I didn't expect. I got 624 Ohm between the pins, and infinite resistance between each pin and ground.
Installed fuel rails and hooked up the engine harness.
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0926.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0938.jpg)
#54
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Tried to install the tensioner with the bolts as listed in PET. I ordered these bolts because I noticed the tensioner had longer bolts installed and figured someone messed up...
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0074.jpg)
wft..?
I have an '85 casting...
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0077.jpg)
with the old bolts...
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0078.jpg)
So is PET wrong or do I have an older part installed?
Anyway, tensioner bolted back up
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0081.jpg)
New cam keys and hubs
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0083.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0084.jpg)
Newly coated cam gears
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0087.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0088.jpg)
Water pump and tensioner arm installed
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0094-1.jpg)
Belt routed, timing in the next days...
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0074.jpg)
wft..?
I have an '85 casting...
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0077.jpg)
with the old bolts...
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0078.jpg)
So is PET wrong or do I have an older part installed?
Anyway, tensioner bolted back up
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0081.jpg)
New cam keys and hubs
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0083.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0084.jpg)
Newly coated cam gears
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0087.jpg)
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0088.jpg)
Water pump and tensioner arm installed
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0094-1.jpg)
Belt routed, timing in the next days...
![](http://i560.photobucket.com/albums/ss48/LeonSpeed/TB%20and%20Top%20End%20Refresh/DSC_0097-1.jpg)
#59
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Thanks! The coating is some special ultra secret stuff, done by Colin (Lizard). I actually don't know what it is other that there are signs of electro plating.
Thanks! Yes I saw that. Loctite blue sounds like a good idea, I wasn't impressed with 40 Nm because the gear can't be locked while torquing, so it is a guess at best.
Thanks! I am working in a pretty dark garage box, so I am hoping that in daylight it will look just right.
Thanks! I am working in a pretty dark garage box, so I am hoping that in daylight it will look just right.