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505 Tech: N9tea Rebuild Part 1
12-18-04
So it has started... the N9t is getting a rebuild. I have no money right now, but it's winter break and i've been wanting to do some car work so i thought i'd start taking it apart. Hopefully i'll be able to source some income soon (ie get a job). That way i'll actually be able to put it back together!
What a nice day to start some engine rebuilding!
I've never had car work go this smoothly... something just isn't right. I was able to pull the intake manifold, head, and exhaust log/turbo out all at once with the help of two friends. It took maybe 3-4 hours of work from the time i fired up the 505 (for the last time in a long time :-( ) to the time the head was off. Not bad! I'm really glad it went so smoothly for once. Here are a few pictures, nothing all that exciting though. I still haven't pinpointed the exact problem with cylinder 1. The headgasket and head looked good so far although i didn't inspect the head very thoroughly yet. I noticed the presense of only one dowl pin between the head and block. It looks to me like there is space for two on opposite corners of the head. Grr.. I will look into that. I still can't say with certainty what the problem is, but as of now it still looks to be the rings. The pistons really don't have all that much carbon buildup on them.. i'm quite pleased and surprised. I remember how bad my civic was when i swapped the head on that thing! yikes.
So that's about it for now. I'll probably spend my time taking more stuff apart and cleaning, then doing some useless stuff like painting the valve cover until i can find a way to make money. The plan is to do some head flow work along the way, as well as rebuild and reseal, do a valve job, balance the bottom end, and all the other normal rebuild basics. I really want the thing to be done right, and hopefully we'll work as much as possible with performance along the way. I'd love to ditch the nasty exhaust log, but that would require a new turbo (which would be nice...and expen$ive..), and lots of very difficult fabrication. I may try it anyway. I am also extremely excited that i will have a peugeot that does NOT leak lots of fluids! MMM! is it really possible? It will be a fun project regardless. Stay tuned.
12-20-04
Further inspection of the head still provided no clue to any possible problems. The head looks like it's still in really good shape. It comforts me to know that at least the head isn't messed up because as any 505 turbo owner knows, the head/headgasket is the bigtime problem spot with these engines.
I noticed that the intake manifold gasket was quite sloppy. Not surprising... When it's reinstalled i must remember to make sure to port match the gasket. There were parts of it that seemed to hang significantly over the head ports. I'll have to check the ports on the manifold vs the head as well and make sure those mate nicely. If not there will be some grinding with the rotary tool.
Like always, one of the exhaust manifold studs/nuts had rattled out. These seem to come out on a lot of 505 turbos. Or is it just me? hmm... I/ll make sure to be extra careful in torquing them down on reassembly.
So, the top end is apart. Next step is to either clean the top end parts up a little, or to pull the block out of the car, leaning towards idea #1 for now.
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