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German Cars have got us another 320iS from Italy for 2006.  Its got full service history up to 2002 and we bought it knowing it required a little mechanical work to make good for spring.  At 180,000 Kilometres we thought it would be prudent to remove the engine to cure an oil leak and check the timing chain tensioners and valve clearances.

We took the engine out in an afternoon and broke it down the following week.  The slight noise turned out to be a broken main valve spring!  -phew no damage done.  The engine is now in a thousand pieces all over the garage:

 

 

 

 

We did a leak test on the head to see how good the valve seats were.  A few leaks showed, so we stripped the head and It now looks as if it had been stood for a while, as surface rust on some valve seats was revealed.  An easy fix here will get the compression back up to scratch - We can't be giving away BHP that easily!.  The pistons, crank and bearings were very good, but whilst it is apart we will fit new rings and bearings.  The timing chain slippers look dodgy but the sprockets are mint.  We will fit a new chain and slippers to keep the sprockets good.  Re-assembly can now begin.

Valves have been lapped in -helped by top rally mechanic `jps`.  Also fitted the crank with new bearings and fitted new piston rings in cleaned out piston grooves.

Update:

Throttle bodies have been stripped and cleaned,  All engine parts have been thoroughly cleaned and are awaiting assembly.  

Whilst the engine is out we have repaired the very common stress cracks on the right hand engine mounting point on the cross-member. 

We pulled the gearbox out.  The rear seals were a little weapy so we have replaced the output and linkage seals after a thorough clean.  The linkage also got a new bush and the guibo also got replaced. It is all reinstalled now and filled with Citroen BV oil (helps the synchro's apparently).

Update:

Some new hoses were required to the breather system / idle control to ensure good vacuum.  Although running okay i suspected it was lean.  I measured the resistance across the blue coolant sender and this confirmed that the cold signal was incorrect.  We fitted a new one and it made a massive difference. 

Here's the motor finally built up and back in the car, we are now running in with normal mineral oil.

A Big thanks to C3bmw for all the parts we`ve required.

24/10/06 Update:

Running well -off to the Isle of Man for Recce.

 

 

 

 

 

 

 

 

 

 

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