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Campro Cps Bottom/internal Modification (completed)


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#1
drexchan

Posted 06 August 2010 - 10:20 AM

drexchan

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One drunken piston refuse to wake up for work after drinking too much sky juice.


and its 'rod' down there swung open a hole on the crankcase wall


Vented hood and an open pod sitting right below the vents caused a serious hydrolock after a heavy rain. Second cylinder drank most of the sky juice and the conrod snapped almost instantly. Conrod cap swung open a 3cm x 5cm hole on the crankcase wall. Piston jammed in the cylinder and that's it.

Supposed to be a repair job on this 2 month old CPS. After some discussion with the owner, we decided to do some minor internal modification since the work and time required has no difference.

In short, the engine will be enlarged to 1639cc from 1597cc. The flywheel, crankshaft and the crank pulley will be balanced and lightened as one assembly. All new pistons and conrods (1 new rod) will be weighed, lightened and balanced.

At this moment, the engine has been completely dismantled to the last pieces, cleaned and sent to be repaired and modified. New oversize pistons, new rings, new bearings, seals and gaskets are already here.

For a week or so, our job is to wipe the car shiny clean. biggrin.gif

CPS intake camshaft with trilobe cam profile. The middle lobe is used when CPS is not activated. Side lobes pushes the valves by few mm further.


Transmission sitting on a stand, holding up by its own mounting.


#2
drexchan

Posted 06 August 2010 - 10:22 AM

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Water Filling the intake manifold


More about the Titanic hole


CPS activation solenoid


#3
drexchan

Posted 06 August 2010 - 10:24 AM

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Hydraulic Valve Lifter


Super long head bolt


New oil seals, bearings, gaskets, piston rings, and a connecting rod


The new 77mm pistons


#4
drexchan

Posted 06 August 2010 - 10:26 AM

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The repaired crankcase wall


Short block, crank assembly and the piston assemblies


Crankshaft, conrods and pistons are installed back into the block. Notice the shiny area on the conrods (1, 3 & 4), due to lightening and balancing process


FEAD block and oil pump being assembled to the short block.


#5
drexchan

Posted 06 August 2010 - 10:28 AM

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Flywheel. Skimmed at the back surface. Even the bolts are indexed in the balancing process


Back in to the engine bay


Installing the engine head


#6
drexchan

Posted 06 August 2010 - 10:31 AM

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THESE ARE SOME PHOTOS TAKEN DURING THE EARLY STAGES OF DISASSEMBLING THE ENGINE.

Oil seals, bearings, piston rings, etc


The new pistons


Piston & Connecting Rods, notice the snapped one



#7
drexchan

Posted 06 August 2010 - 10:33 AM

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Woke Up!!


Organizing the wire harness took me quite a while. It looks almost untouched.

FIRST START VIDEO

Stable vacuum level is a good sign for good compression and no abnormal leak over the piston rings.


Water temperature after a series of hard running-in drive. Healthy.


Engine oil temperature after a series of hard running-in drive. Healthy.


Did about 40km so far. This was taken at exactly 20km from the 'resuscitation'.



#8
drexchan

Posted 06 August 2010 - 10:34 AM

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Finally, discharged from the hospital.


The car has been serviced after its first 1000km run-in. It's getting smoother day by day and the owner is going to dyno-test it soon.

#9
vr2turbo

Posted 06 August 2010 - 11:20 AM

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QUOTE (drexchan @ Aug 6 2010, 10:34 AM) <{POST_SNAPBACK}>
Finally, discharged from the hospital.


The car has been serviced after its first 1000km run-in. It's getting smoother day by day and the owner is going to dyno-test it soon.

Bro. Drex,
Nice write up....... smile_thumbup.gif

heh! heh! am interested also what amount of hp and torque gain from the new 1639cc power plant...... smile_wink.gif

Question:
The Vented Hood and Open Pod able to send in so much sky juice to flood that combustion chamber? Then those who Mod, better place the open Pod further away..... smile_shock.gif

#10
drexchan

Posted 06 August 2010 - 11:49 AM

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the mushroom was grown in the wrong place. smile_tongue.gif