13/01/07
New year, new engine. I haven't touched the car for over a month, so I'd better get on with it. I haven't been sat around doing nothing, honest. While waiting for the right engine to turn up at a breakers, I've been busy helping a friend doing some decorating, which has taken longer than anticipated.
Dean at Allcars rang me on the 5th of January to say he'd got an accident-damaged 1998 Rover 218 VVC coupe in for breaking. He said that the car was immaculate and had only done 62,000 miles. I thought the mileage sounded suspiciously low, but agreed to view the car the next day. Sure enough, it was obviously a mint example before the accident. The engine looked and sounded in very good health, with no rattles and nice clean oil and coolant. I gave him a deposit and arranged to collect the engine on the following Saturday...
...and here it is, safely in my garage. The engine, loom, MEMS ECU, 5AS alarm module and relay unit cost £500+VAT. I probably won't use the 5AS module. For simplicity, I intend to use a MEMS Immobiliser Interface from Talon Sportscars. I also need to source a different flywheel - from a late 90s 216 with MEMS 1.9 and a 200mm clutch. The new engine didn't come with an alternator, but I thought I'd use the one from the Metro. However the connections on the back are completely different, so I may have to fork out for the correct alternator.
Bolting this engine in will be the easy part of the conversion, but the electrics and cooling will require some thought. The fun starts next weekend.
16/01/07
Actually, the fun has already started. I'm still needed for more decorating duties at weekends, so I'll try and get some work done on the Firefox on weekday evenings. I removed the flywheel last night and managed to pop into Allcars on my travels this morning. Luckily, Dean had the exact flywheel I needed. Later, I visited Millards and ordered a suitable clutch, along with new aam belts, water pump, thermostat, spark plugs and oil and filter.
The rear of the 1.8 flywheel (PSD 10107), showing the missing pole pattern in relation to the dowel hole.
The front of the 1.8 flywheel. It measures 293mm across from tip to tip and uses a 215mm clutch plate.
The rear of the 1.6 flywheel (WFM 1972)...
...and the front. 260mm across, 200mm clutch. I'll give it a clean tomorrow night.
17/01/07
Cleaned the flywheel, then used a tap to clear out the flywheel bolt threads in the end of the crankshaft. I should be passing the local MG/Rover dealer on Friday, so I hope to get six new flywheel bolts then.
18/01/07
Fitted the new water pump and the front (O/S) timing belt.
21/01/07
Fitted the new spark plugs, then made a cam sprocket holding tool and fitted the new rear (N/S) timing belt.
27/01/07
After a morning's work, the old 1.4 engine is finally out.
Next weekend's job is to temporarily fit the gearbox to the 1.8 engine and drop it in here. The new engine is slightly taller than the old one, due to the Hydraulic Control Unit for the VVC mechanisms. I may need to fiddle about with the engine mountings again, to ensure it all fits under the bonnet.
28/01/07
Why wait 'til next weekend? I unexpectedly had some free time this morning, so I removed the gearbox from the 1.4 engine, bolted to the 1.8 and dropped it into the engine bay. The good news is that the HCU (arrowed) does fit under the bonnet.
The bad news is that the bonnet touches the cam belt cover. The picture above is a view from the driver's seat, looking forward under the partially-opened bonnet. The front outer edge of the top cover (arrowed) is the problem area. I didn't have the covers fitted to the old 1.4 engine, so this wasn't an issue. I'd like to have full protection for the belt on this more valuable engine, so the engine mounts are going to need some more modifications.
04/01/07
Apart from the lack of cam belt cover clearance, all was well, so I've removed the engine and gearbox again. I managed to get some flywheel bolts (PSK 10005) last week, so I've refitted the 1.6 flywheel using the new bolts.
The new 1.6 clutch in place. It's not possible to use a clutch aligning tool with this crankshaft/flywheel/clutch combination, so I had to centre the clutch plate by eye. The gearbox is light enough to easily fit it on my own, but I used these two lengths of 12mm studding to help support and position the 'box on its way in.
Before refitting the gearbox to the engine, I used a piece of 8mm studding to hold the clutch arm in place. If the arm moves before the gearbox is fully home, the release bearing can become unclipped from its fork. Thankfully, the 'box went straight on without a fight. Next job was to replace the old 88° thermostat with a new 82° version. The engine loom was then refitted and the whole lot dropped back into the engine bay.
10/02/07
With the new engine in place, it's time to start wiring it up. This is the existing wiring for the 1.4 engine.
The main loom from the 1.8 engine to the ECU and relay module will go through the existing hole in the panel. I had to cut a new hole (arrowed) to take the bulkhead loom (the top cable in this picture). On the donor car, the main loom curves round to the N/S/F of the engine bay, where the ECU and relays are located. I'll site the ECU and relay unit somewhere under the scuttle on the Firefox, so both looms have to go through the front bulkhead.
The end of the bulkhead loom, with the connector chopped off. There were 13 wires in there, but I'll only need 7 of them:
| Colour | Function | Notes |
| Yellow/Green | +Supply to fuel pump from relay unit | |
| White/Brown | Oil pressure warning light | |
| White/Black | Signal to tachometer | |
| Brown/Yellow | No charge warning light | |
| Green/Blue | Coolant temperature gauge | |
| White/Red | Starter relay coil +signal from ign. switch | |
| Black/White | Starter relay coil earth | |
| Blue/Slate | Coded signal from alarm ECU | |
| Green/Brown | +Supply to reverse light switch | |
| Green/Yellow | Feed to reverse lights from switch | |
| Green/Pink | +Supply to MEMS ECU and speed sensor | |
| White/Orange | Speed sensor signal to speedometer | |
| Slate/Blue | Cooling fan relay |
After removing the top metal scuttle panel to improve access, two new multi-connectors were crimped onto the end of the loom.
Not much to show for a whole day spent in the garage, but I'm pleased with the progress so far. Next weekend I need to find somewhere to fit the MEMS ECU and relay unit.
13/02/07
Managed to spend some time in the garage this evening, so I've refitted the starter motor, exhaust system and gear linkages.
14/02/07
Refitted the N/S/F driveshaft, suspension and wheel, then removed the battery for charging.