C1J bottom end rebuild

[tiff_lee]

Hopefully going to get some time down south later this month or next where they have a pretty good car club on the base so I was going to take advantage of my time there and rebuild my bottom end.

The block that was in my car cracked (some may of seen the thread/pics) and Gary (schwartz) kindly donated me his old block which was in good condition bar the two damaged pistons & liners so the idea was to transfer my good pistons/liners into the good block.

Anyhow I was wondering what else I should be looking to do while I've got it in bits, I dabbled with an engine rebuild years ago on an A series lump but didn't really take it too seriously. Should I be just replacing shell bearings or getting regrinds and oversized bearings as necessary? what about piston rings and liners? Basically just after advice from anyone (which is probably alot of you) who has rebuilt a block before.

I'm not looking to go silly or anything I just want to rebuild the block for track/road use (not everyday car) so perhaps a different cam? when all is finished i'll also be fitting a larger turbo, adjust fuelling accordingly etc

[SCHWARTZ]

all depends on the condition of the parts if crank has no scoring(and is in tollerance) and the shells look okay just fit new shells and dont worry about a re-grind. The crank in the block i gave ya should be ok so worth wile taking a look at that also New piston rings (if the pistons are ok) new oil pump.

[tiff_lee]

Yea I was gonna strip both blocks and see the condition of both and pick the best.

Can you re-use old liners providing there is no damage to them etc? What kind of power levels are the standard internals good upto?

[SCHWARTZ]

over 200bhp on standard internals is the norm i think. liners are fine to re-use providing there is no lip worn into them. dest to check them with a dial gauge to see. Haynes manual is your friend.

[tiff_lee]

Haynes manual is your friend.

that's a bit controversial, the haynes book of lies my friend!?

[SCHWARTZ]

that's a bit controversial, the haynes book of lies my friend!?

that will (if its not lies) have the measurements that tou will need to know.

[tiff_lee]

What is the best clutch to fit if i'm aiming for more power?

[SCHWARTZ]

volvo 440 460 480 clutch seems to be a good upgrade (200mm version) and the fork extension. there was a group buy for some four paddle clutches worth a look to see if you could get one of those

[tiff_lee]

Do they fit onto the standard R5 flywheel? and fork extension?

[Markey Mark (BD)]

Fork extension is for wimps!

If you want a softer pedal feel them yes fit the extension but its not neccessarily needed.
The Volvo 480 turbo clutch (valeo item) will take a fair bit, paddle friction plate will handle more though

[SCHWARTZ]

yep there are 2 versions 200mm(the one you want) is an early version. Later 215mm version is no good for ya. fork extension is from a volvo 440 460 480 and is basicaly the same as the r5 fork but longer there is a bracket that bolts to where the cable goes through originaly this softens the pedal (soft pedal conversion).

[tiff_lee]

Oh it's to make the pedal easier to press...well after having pug 306 diesels i'm sure I now have one leg bigger than the other anyhow!

Paddle friction plate...sounds expensive, what kind of power levels is the 480 clutch good for?

[SCHWARTZ]

again would do you well for over 200bhp (aparently)

[tiff_lee]

Over 200bhp blimey i'm not really too fussed in going that far so looks like 480 clutch it is then, cheers guys

[SCHWARTZ]

Fork extension is for wimps!

best get one sorted then

[tiff_lee]

best get one sorted then

touche'

[tiff_lee]

Where's the best place to source the 480 clutch, gsf?

Also any recommendations for a replacement cam?

[Shane P]

Where's the best place to source the 480 clutch?

https://www.rtoc.org/boards/showthread.php?t=18414

[Shane P]

Where's the best place to source the 480 clutch, gsf?

https://www.rtoc.org/boards/showthread.php?t=18414

[tiff_lee]

Cheers Ganja I did see that but wasn't sure if it was the same thing...so uprated R5 clutch is a volvo 480??

Plus had no idea what they retail for to judge whether that was a good price or not.

[Shane P]

Cheers Ganja I did see that but wasn't sure if it was the same thing...so uprated R5 clutch is a volvo 480??

Plus had no idea what they retail for to judge whether that was a good price or not.

440/460/480 Turbo More info :

https://www.rtoc.org/boards/showthread.php?t=4749

It's a good price from a very helpful trustworthy member

[tiff_lee]

Oh no doubt, I wasn't questioning him as a member just wanted to sure of what I was paying or looking to buy etc.

Thanks for directing me to that article.