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enerider's 1.6L build

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enerider

Post subject: enerider's 1.6L build

Posted: Sun Sep 26, 2010 8:36 pm

Joined: Wed Sep 29, 2004 1:21 am
Posts: 423
Location: Invercargill, New Zealand

Hello everyone!

One of my Barina GTI's is about to get some well-deserved attention, and a 1.6L 16V block is going to be on it's way next week (once I pay the person to ship it down from Manuwatu

).

So I'm going to take the plunge and pop my soon-to-be-rebuilt 16V G13B head onto the 1.6L block.

The cylinder head is with the Cylinder Head Clinic and will need the exhaust valve guides replaced. However due to the excessive pricetag on the OEM guides we're going to be sourcing some alternatives - which I believe to be Honda motorbike valve guides! :!:

There is also a little nick in the cylinder head which is going to be filled and machined and the passage that reroutes exhaust gases from the exhaust manifold to the intake (where it just ends up meeting solid metal) is going to be plugged off as the intake side of the passage appears to have been eaten out somehow.

The valves will then be checked (as the previous owner was driving and snapped the cam belt) and replaced as required.

Other details will be forthcoming - the body will be stripped right down for a full repaint as the paintwork on the old fella is rather faded and shot, so will be going a nice glossy black

Will update when there is progress

_________________
Before downloading, you may want to read this: http://www.teamswift.net/viewtopic.php?p=246047
Mark 1 Workshop manual: http://d01.megashares.com/dl/qAE1O4k/SA ... Manual.PDF
mk2/mk3 GTI manual: http://d01.megashares.com/dl/7pbE6NH/Su ... K2and3.zip

Rock stock 1988 AA33S SA413 HEJ574 Holden Barina GTI rebuild complete! http://www.teamswift.net/viewtopic.php?f=31&t=39669 - Deceased and stripped for parts
1987 AA33S SA413 HEJ574 Holden Barina GTI MK1 - gone

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suprf1y

Post subject: Re: enerider's 1.6L build

Posted: Sun Sep 26, 2010 11:00 pm

Moderator

Joined: Sun Feb 23, 2003 4:16 am
Posts: 7335
Location: Ontario, Canada

I think those guides are the same as the 89+ G10. I don't know what your pricing is like there, but I have bronze manganese guides in stock.

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Contact 3tech: g10pro@rocketmail.com

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enerider

Post subject: Re: enerider's 1.6L build

Posted: Mon Sep 27, 2010 2:56 am

Joined: Wed Sep 29, 2004 1:21 am
Posts: 423
Location: Invercargill, New Zealand

Guide measurements as I far as I am aware are 45mm, 5.5mm hole up the centre for the original parts.

The Honda guides are 43mm with a 5mm hole in the centre.

What would be the pricetag on your guides? I'll need 8

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suprf1y

Post subject: Re: enerider's 1.6L build

Posted: Mon Sep 27, 2010 7:24 am

Moderator

Joined: Sun Feb 23, 2003 4:16 am
Posts: 7335
Location: Ontario, Canada

$4 each.

I can look at shipping, if you want.

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Contact 3tech: g10pro@rocketmail.com

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enerider

Post subject: Re: enerider's 1.6L build

Posted: Mon Sep 27, 2010 4:36 pm

Joined: Wed Sep 29, 2004 1:21 am
Posts: 423
Location: Invercargill, New Zealand

You sir, have a PM coming your way!

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enerider

Post subject: Re: enerider's 1.6L build

Posted: Wed Sep 29, 2010 7:39 pm

Joined: Wed Sep 29, 2004 1:21 am
Posts: 423
Location: Invercargill, New Zealand

G16A bottom end will be getting shipped tomorrow, so I'll have yet another block roaming the shed soon (as long as nothing goes drastically wrong during shipping).

For now, I'll have to clear the 13BT rotary out of the way to make room for the current (and slightly more affordable) project underway

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enerider

Post subject: Re: enerider's 1.6L build

Posted: Thu Sep 30, 2010 6:15 pm

Joined: Wed Sep 29, 2004 1:21 am
Posts: 423
Location: Invercargill, New Zealand

After a fair amount of calling, searching and bugging suprfly, I might have tracked down some replacement valve guides that we will be able to machine to size!

www.kerzan.co.nz are the people I will be getting 8 universal valves guides from, which after we've received them we'll machine down to the right size.

The measurements for the valve guides in my MK1 G13B cylinder head are as follows:

5.45mm bore (workshop manual says 5.5mm - but the valve stem's actual measurement is 5.45mm - 5.5mm hole would make it slap around too much)
11.06mm outer diameter
43mm length

suprfly has some G10 valve guides which shared the same bore and O.D but were only 32mm long, which would result in 6mm of countersunk valve guide which would no doubt affect heat dissipation though the valve stem to the cylinder head (smaller contact area for the heat to travel through). Scarily - suprfly said that the G13B and the 89+ G10 shared the same part number for the valve guides! :huh:

Just thought I'd flick this tidbit of information up.

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enerider

Post subject: Re: enerider's 1.6L build

Posted: Sun Oct 03, 2010 4:46 pm

Joined: Wed Sep 29, 2004 1:21 am
Posts: 423
Location: Invercargill, New Zealand

Well, some more investigation into the cylinder head yielded 7 bent exhaust valves

although I've got little idea how the 8th valve escaped punishment - maybe that lifter just happened to be a little less extended than the rest? Oh well, one less exhaust valve to buy :lol:

I just hope we can source some valves easy enough!

G16A bottom end will hopefully have arrived today - will have to visit the local freight depot to see where it is at

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suprf1y

Post subject: Re: enerider's 1.6L build

Posted: Sun Oct 03, 2010 7:11 pm

Moderator

Joined: Sun Feb 23, 2003 4:16 am
Posts: 7335
Location: Ontario, Canada

I think I misunderstood.
You're putting a Mk1 GT head on?

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Contact 3tech: g10pro@rocketmail.com

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enerider

Post subject: Re: enerider's 1.6L build

Posted: Sun Oct 03, 2010 11:59 pm

Joined: Wed Sep 29, 2004 1:21 am
Posts: 423
Location: Invercargill, New Zealand

suprf1y wrote:

I think I misunderstood.
You're putting a Mk1 GT head on?

Yup.

And the bottom end isn't going to be here until the end of the week it looks like, so I'll just have to wait some more.

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Dattman

Post subject: Re: enerider's 1.6L build

Posted: Mon Oct 04, 2010 6:41 am

Teamswift Racer

Joined: Fri Apr 02, 2004 5:56 am
Posts: 1934
Location: Chur chur the 'Shaky State' NZ

Did you ever think about building a g15 instead??? the NZ land speed record for upto 1500cc cars is a lousy 212kph set by a Maserati about 40 years ago, since you live in Burt Munroe country down there :mrgreen:

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gamefoo21 wrote:

But but the Ricer gods demand I drag the the floor on the pavement and think it's hot shit for suspension!

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suprf1y

Post subject: Re: enerider's 1.6L build

Posted: Mon Oct 04, 2010 5:21 pm

Moderator

Joined: Sun Feb 23, 2003 4:16 am
Posts: 7335
Location: Ontario, Canada

I was wrong. I misunderstood which head you were using.

I have these in stock.

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Contact 3tech: g10pro@rocketmail.com

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enerider

Post subject: Re: enerider's 1.6L build

Posted: Mon Oct 04, 2010 8:13 pm

Joined: Wed Sep 29, 2004 1:21 am
Posts: 423
Location: Invercargill, New Zealand

suprf1y wrote:

I was wrong. I misunderstood which head you were using.

I have these in stock.

Sorry for the misunderstanding!

I'll hit you up next time for some bits (you know there will be a next time! :lol:

Dattman, I don't think I could have found a G15 bottom end easily? (or will Trademe prove me wrong yet again?!)

In any case, the bottom end has arrived - and there really isn't a terrible amount of difference on the face of it...

Will document with photos as stuff happens

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Dattman

Post subject: Re: enerider's 1.6L build

Posted: Wed Oct 06, 2010 1:14 am

Teamswift Racer

Joined: Fri Apr 02, 2004 5:56 am
Posts: 1934
Location: Chur chur the 'Shaky State' NZ

Rex Russell wreckers has 2 or 3 g15's, usually wants about $400, you can usually sell the head for a couple of hundred if you don't want or need it.

It might be worth looking at either the Calimini (sp) or suzitech crowds as I'm pretty sure you can get an adapter plate to go from a 'big' block to a 'little' gearbox, there are plenty of lj413's running vitara engines, might save your dad re-inventing the wheel so to speak.

_________________

gamefoo21 wrote:

But but the Ricer gods demand I drag the the floor on the pavement and think it's hot shit for suspension!

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enerider

Post subject: Re: enerider's 1.6L build

Posted: Wed Oct 06, 2010 9:24 pm

Joined: Wed Sep 29, 2004 1:21 am
Posts: 423
Location: Invercargill, New Zealand

Ah well, a bit late for me to go get a G15 bottom end now Dattman

The adaptor plate won't be a huge job for us (plasma cutter is good like that, as is having a workshop in the family that is kitted out enough to handle most feats of engineering :mrgreen:

). In fact I'm confident I could apply the necessary elbow grease myself to make the plate.

My only query would be the material to make the plate out of.

To my mind a 6mm thick mild steel should do the trick. Thicker stuff can be easily enough sourced if recommendations go toward something with a bit more thickness/strength to it!

I'm also guessing that there would be a couple of extra bolts down below to where the "wings" are for near the bottom of the block, two bolts going from block to plate and a futher two coming from gearbox to plate.

Time will tell as and when I get that far, first there is the work to the cylinder head (and work done for the UT Barina) to square up - gotta pay people who do stuff for you!

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marko

Post subject: Re: enerider's 1.6L build

Posted: Wed Oct 06, 2010 9:25 pm

Joined: Thu Nov 12, 2009 12:20 pm
Posts: 9
Location: Australia

Dattman is right re: the adaptor plate.
They're made locally in NZ infact.

Look up "Ben-T adaptor plate". He trades on forums (outerlimits / auszookers) and ebay.
They're designed specifically for the vitara g16b into sierras, but he'll have the part or be able to manufacturer it for a price.
Of course, if you're motivated enough to do the work yourself, it's the best way.

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enerider

Post subject: Re: enerider's 1.6L build

Posted: Wed Oct 06, 2010 10:40 pm

Joined: Wed Sep 29, 2004 1:21 am
Posts: 423
Location: Invercargill, New Zealand

marko wrote:

Look up "Ben-T adaptor plate". ...

http://auszookers.com/index.php?name=Fo ... ic&t=15434

Cheers for that marko!

From this I have now got a confirmed hit on a 6mm thick plate - now I just have to figure out what to make it out of!

Mild steel to my mind would suit - easy enough to locate some and treat it so it doesn't rust out - or find some other material to make one out of!

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enerider

Post subject: Re: enerider's 1.6L build

Posted: Tue Oct 12, 2010 1:56 am

Joined: Wed Sep 29, 2004 1:21 am
Posts: 423
Location: Invercargill, New Zealand

Right - not much happening at present because I'm gearing up for some other stuff :mrgreen:

Replacement valves, valve guides and head gasket have arrived.

Just have to machine the valve guides to size!

Head gasket is the standard G16A Vitara gasket. It's not the 1.8mm thick one but 1.25mm thick - but the part numbers line up and everything else seems to match when compared to block and cylinder head. So I guess I'll be going with that for now!

Money being reasonably tight at the moment means plans for this project are going to be postponed for a little bit. Not too long though - just means it could be a month's delay.

Ah well, I'll get there!

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enerider

Post subject: Re: enerider's 1.6L build

Posted: Wed Oct 26, 2011 6:59 pm

Joined: Wed Sep 29, 2004 1:21 am
Posts: 423
Location: Invercargill, New Zealand

LONG OVERDUE UPDATE:

Well, after swapping my 2nd GTI for another car I ended up getting it back again! Sadly in a very sorry state...

The person who had purchased my 2nd GTI off my friend decided the best way to treat such a car was to do reverse doughnuts at the beach while at the rev limiter. #2 piston conrod did not like this idea, broke in half and punched out both sides of the block it could reach, breaking the main oil line. Also broken were the water jacket (antifreeze in the oil) and #2 piston skirts.

Sooo...after hearing about it's abrupt ending I immediately jumped in with a money offer and got it back and promptly raided it for the parts.

Which means I get my newish shock absorbers back, doors, rear hatch, interior, spare ECU and another 16v cylinder head to play with as well as many other parts. My dad recieved the original 13" Alloys and tires for his car and the rear axle assembly for the 2nd GTI which I believe there are plans for a trailer.

As for the shell, it's on its way to the graveyard.

What does this mean for the 1.6L build? It means it'll happen a whole heap sooner than expected as I now have a wide selection of parts to choose from which will permit me to make a good job of this.

I already have the paint to repaint the body with.

Stay tuned for further progress! :mrgreen:

Farewell, my 2nd GTI. I am truly sorry your end came the way it did.

EDIT: Whoa - just looked at the date and realised that a month turned into a year before I realised! How time flies!

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enerider

Post subject: Re: enerider's 1.6L build

Posted: Sun Jun 24, 2012 10:24 pm

Joined: Wed Sep 29, 2004 1:21 am
Posts: 423
Location: Invercargill, New Zealand

Well that's the end of my Swift story - car has been sold down the river as I can no longer sustain it.

Some parts available.

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Dattman

Post subject: Re: enerider's 1.6L build

Posted: Mon Jun 25, 2012 2:01 am

Teamswift Racer

Joined: Fri Apr 02, 2004 5:56 am
Posts: 1934
Location: Chur chur the 'Shaky State' NZ

Sorry to hear that mate, would of been nice to see a 'big block' mk1 around these parts.

_________________

gamefoo21 wrote:

But but the Ricer gods demand I drag the the floor on the pavement and think it's hot shit for suspension!

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enerider

Post subject: Re: enerider's 1.6L build

Posted: Mon Jun 25, 2012 4:02 pm

Joined: Wed Sep 29, 2004 1:21 am
Posts: 423
Location: Invercargill, New Zealand

Yeah, I would have loved to be able to complete it but I neither had the money or the time sadly

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