BennehBoy's D2 adventure

I just ordered bolts, shells, thrusts, stem seals and gasket kit.

Haven't ordered the chain.

Looks like the job just grew a bit.

You're all big bullies

And I'm going to join in with the kicking too - seeing as you're already down.

You've taken it this far, so you may as well do the chain.

I can help with a valve compressor and might be able to drop it over at the weekend. It's just a standard vanilla flavoured one, but worth giving it a go.

Oh! How you will thank me when you're grinding all those valves back in again!

Also I am in love with your new exhaust manifold and it feels the same about me. We will probably have to run away together. Sorry Mate.

I won't need to regrind the valves if I'm reusing?

Chain ordered, bah ####ing humbug.

Oh and Maaarrghk, a borrow of your spring compressor would be greatly appreciated - coffee/tea and chin wag will be provided by me. PM coming your way.

Bennehboy said:

I won't need to regrind the valves if I'm reusing?

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yes you will,if you want to do it right.now gerron wi it.

Bennehboy said:

Chain ordered, bah ####ing humbug.

Oh and Maaarrghk, a borrow of your spring compressor would be greatly appreciated - coffee/tea and chin wag will be provided by me. PM coming your way.

Click to expand...

yaaaaaayyyyyy.now you know how it feels like me to be constantly nagged at.my doris a feckin master at naggin.

OK, since I'm blowing all this cash I need to make sure this thing is going to last....

The head that's on is remanufactured, so I'm guessing it's been skimmed at some point.

Thought I'd better double check the flatness of the mating face...

So straight edge out and fettle with a 0.05mm feeler gauge...


And it pushes the edge all the way along on either corner to corner check, phew.

Bennehboy said:

OK, since I'm blowing all this cash I need to make sure this thing is going to last....

The head that's on is remanufactured, so I'm guessing it's been skimmed at some point.

Thought I'd better double check the flatness of the mating face...

So straight edge out and fettle with a 0.05mm feeler gauge...

And it pushes the edge all the way along on either corner to corner check, phew.

Click to expand...

you need a longer straight edge,that one you are using could give you a false reading.needs to be corner to corner ideally.

gemsdad said:

you need a longer straight edge,that one you are using could give you a false reading.needs to be corner to corner ideally.

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Yeah I checked it from either end too, figured that would give me as near as dammit.

Will see what's at the factors tomorrow, it's only money after all

gemsdad said:

yes you will,if you want to do it right.now gerron wi it.

Click to expand...

Seriously, will I need to regrind the existing valves? Happy to do it, just didn't think it would be needed... is this because they will probably go back in rotated from where they've been sat for a while?

Bennehboy said:

Seriously, will I need to regrind the existing valves? Happy to do it, just didn't think it would be needed... is this because they will probably go back in rotated from where they've been sat for a while?

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tis your call mate,but iknow what i would do in that situation,they will only need a light grind anyway.

Some pics of the cylinder honing...

Rear side of pot 5:


Front side of pot 5:

Couple of photos to show the difference between the stock and allisport manifolds...

Neck length is identical, bu the runners merge closer to the turbo flange...

nice,how much was the manifold?

It's always good practice to grind the valves in. You should get away with just using the fine grade paste on the inlets. It's usually the exhausts that are worse.

Can't get your pm here at work so will try to access it at home tonight.

And stop posting revenge porn pictures of that manifold. We want to be together and there's nothing you can do about it.

gemsdad said:

nice,how much was the manifold?

Click to expand...

Google so I don't incriminate myself in front of SWMBO

Maaarrghk said:

It's always good practice to grind the valves in. You should get away with just using the fine grade paste on the inlets. It's usually the exhausts that are worse.

Can't get your pm here at work so will try to access it at home tonight.

And stop posting revenge porn pictures of that manifold. We want to be together and there's nothing you can do about it.

Click to expand...

Ceasing and desisting.

I've had a new QH water pump sat in my shed for over a year, they are a notorious pain in the bum to fit.

Since the engine is in bits now's the ideal time to install it...



Cover bolts removed:


This side of the pump looks good, but the impeller has a lot of play, suspect the bearing has failed allowing coolant to drain through and out of the relief holes in the back of the PAS casting:


As suspected the bearing is shot!


Cover mating face cleaned up a bit:


Internals cleaned up and mating faces scotchbrited:


The new seals are laid atop a thin bead of RTV:


And back together, bolts just nipped up to 9nm:

Bennehboy said:

Google so I don't incriminate myself in front of SWMBO

Click to expand...

ya wimp,pm then.