16v conversion Fiat 2 liter rally engine - updated 02 Oct 08

Crank, rods, sealing, pistons, block, flywheel etc
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Guy Croft
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16v conversion Fiat 2 liter rally engine - updated 02 Oct 08

Post by Guy Croft » Fri May 02, 2008 12:45 pm

Latvian National Rally full-spec GC 16v conversion 2 liter unit complete.


Spec includes all the 'usual suspects' you'd expect from GCRE - nitrided GC spec steel billet cams, D16 HC forged pistons, GC/Cunningham race rods, alloy sump, steel flywheel, 3 stage dry sump.

GC
Attachments
OSC 16v 011.jpg
Built short unit, minus sump fittings but otherwise near complete.
OSC 16v 011.jpg (110.99 KiB) Viewed 11629 times
OSC 16v 012.jpg
ex side view, dry-sump scavenge ports will go in the front lower sump section.
OSC 16v 012.jpg (109.57 KiB) Viewed 11626 times
OSC 16v built.jpg
engine now with sump scav fittings in place
OSC 16v built.jpg (431.61 KiB) Viewed 10264 times
OSC 16v alloy sump prep (4).jpg
Natasha bolting the slotted windage tray in place. The scav fittings have a removable gauze trap integral to the male-male union screwed into the sump
OSC 16v alloy sump prep (4).jpg (440.44 KiB) Viewed 10256 times
Typical parts and service 16v conv.doc
Word document intemising the full list of parts and services performed on this engine at GCRE
(39.5 KiB) Downloaded 544 times
OSC 16v 002.jpg
OE 16v head gasket and GC D16 HC forged pistons
OSC 16v 002.jpg (113.33 KiB) Viewed 10223 times
OSC 16v 005.jpg
checking cam full lift using a long finger dti on the bucket, protractor is on the crank. You can nonly do this with belt fitted.
OSC 16v 005.jpg (110.63 KiB) Viewed 10211 times
OSC 16v 003.jpg
removing the dummy head bolts after offering-up the head, cams are steel billet profiles by Piper, beautifully made, with Vauxhall XE 16v tarmac rally profiles. Lift is so high all the bucket bores had to be deepened.
OSC 16v 003.jpg (115.26 KiB) Viewed 10203 times
OSC 16v cam relief.jpg
a certain amount of relieving work needed in the head to allow the big cam lobes to clear..
OSC 16v cam relief.jpg (118.26 KiB) Viewed 10200 times
OSC 16v dry-run shimming.jpg
shimming up using ordinary capscrews to hold the cam caps in place
OSC 16v dry-run shimming.jpg (117.36 KiB) Viewed 10195 times
OSC 16v inlet full lift true.jpg
inlet cam lift after shimming-up
OSC 16v inlet full lift true.jpg (114.58 KiB) Viewed 10186 times
OSC 16v final bpf test.jpg
full-spec head with OE standard valve sizes on final confirmatory flow test (BPF)
OSC 16v final bpf test.jpg (113.66 KiB) Viewed 10175 times
OSC 16v crank prep_01.jpg
all the usual GC crank mods, mod oilways, tap & plug, polish, balance with OSC's own steel flywheel, dowel
OSC 16v crank prep_01.jpg (118.72 KiB) Viewed 10170 times
OSC 16v inlet valve event closeup.jpg
OSC 16v inlet valve event closeup.jpg (116.82 KiB) Viewed 10161 times
OSC valve-valve proximity check.jpg
here cheecking the valves don't clash, vital with narrow LCA, the inlets are fully assembled and the ex valve is free
OSC valve-valve proximity check.jpg (111.35 KiB) Viewed 10158 times
OSC 16v dry-build (13).jpg
Modelling clay in the VRs tells me the proximity vertically (in the plane of the valve stem) and radially with the head on when the engine is swung over two revolutions. Absolutely essential!
OSC 16v dry-build (13).jpg (109.6 KiB) Viewed 10154 times
OSC 16v pistons and rods in (4).jpg
view of the worlds' finest race rods and pistons - Cunningham/CP
OSC 16v pistons and rods in (4).jpg (113.69 KiB) Viewed 10142 times

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OSC 16v dry sump bracket and pump dry-build (14).jpg
OSC 16v dry sump bracket and pump dry-build (14).jpg (113.07 KiB) Viewed 10139 times
OSC 16v dry sump bracket and pump dry-build (13).jpg
OSC 16v dry sump bracket and pump dry-build (13).jpg (114.61 KiB) Viewed 10128 times
16v aux ds pulley mods to dry sump (1).jpg
aux d/s pulley is dowelled to centre-up pump drive pulley
16v aux ds pulley mods to dry sump (1).jpg (117.19 KiB) Viewed 10125 times
dry sump bracket and pump dry-build (2).jpg
drive pulley machined to accept dowel
dry sump bracket and pump dry-build (2).jpg (114.11 KiB) Viewed 10151 times
aux ds shortened 1.5mm.jpg
shaft machined to get perfect 1" belt alingment without chafing on flange of the steel aux d/s pulley. Plastic ones fit fine but these ones can need modification
aux ds shortened 1.5mm.jpg (113.43 KiB) Viewed 10110 times
shortened aux ds needs housing fitted without gasket to clear seal.jpg
having shortened the aux d/s there is a risk of the back of the pulley rubbing on the seal, but not if you leave out the gasket and used a good grade of automotive RTV sealant instead
shortened aux ds needs housing fitted without gasket to clear seal.jpg (112.33 KiB) Viewed 10123 times
OSC 16v rear 4 oilways blanked off with M8 grubscrews and Loctite Hydraulic sealant.JPG
Rear 4 (redundant) oilways blanked off (red box shows the two centre ones). The are not needed on the 16v conv, the head is fed from the front two only. No point risking a leak here..
OSC 16v rear 4 oilways blanked off with M8 grubscrews and Loctite Hydraulic sealant.JPG (57.86 KiB) Viewed 10117 times
Typical parts and service 16v conv.doc
Detailed engine spec in Word format
(39.5 KiB) Downloaded 542 times

Guy Croft
Site Admin
Posts: 5039
Joined: Sun Jun 18, 2006 10:31 am
Location: Lincoln, UK
Contact:

Re: 16v conversion Fiat 2 liter rally engine - updated 02 Oct 08

Post by Guy Croft » Sat Nov 08, 2008 9:35 am

Finished unit ready to ship with GC M16 inlet manifold modified to take Jenvey ITBs (individual throttle bodies), the manifold can be still be adapted for carbs if reqd for back-back test, hence retention of the original outer shape.

GC
Attachments
GC 001.jpg
GC 001.jpg (114.59 KiB) Viewed 9735 times
GC 004.jpg
GC 004.jpg (109.47 KiB) Viewed 9730 times

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