360 story and engine rebuild

Bebs

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3,265
Wow. This seems like Pandora's Box! I'm guessing you've instructed them to just rebuild anything and everything they can find thats wrong?

Otherwise it feels a bit like going in to fix a broken finger and ending up with a heart transplant!
As oneball says, it could have been a lot worse.. very lucky escape first of all what with the chunk of metal from the gear coq and the floating butterfly screw luckily trapped in the corner of the inlet.
The cylinders themselves are fine so negate the need for new sleeves (extremely costly) the pistons and the rings are ok also negating the need for new ones (again, extremely costly). The crank we were able to polish up negating the need for a new or used one at £3500-6500.
There was always going to be bits that needed replacing at 20 years old and 105,000 miles but AV are doing their absolute best to source used bits and or resurfacing f.eks. The heat shields that are partly worn through rather than just opting for new ones at vast costs.
Of course ultimately it will be 5 figures, there’s no getting around that as I also need a new clutch, release bearing, ring gear, air con compressor and various other bits.
However, from the outset I had agreed with Aldous that if we were going to take everything apart, then we might as well do it properly give the high mileage.
 

Bebs

Member
Messages
3,265
Right hand side cams prior to assembly64234

Rather than use the standard factory cam settings marked on the pic below, AV are spending a lot of time dialling in the exact settings with dial gauges and degree wheel on the crank. All four cams are set using this method.

64235642386423664237
Cam setup is critical on these engines and can make a huge impact on power output.
 

philw696

Member
Messages
25,113
AV is the man and doing it totally correctly.
It can be very time consuming but also very rewarding.
A lot easier I can tell you on a stand than in situ.
It's the same doing variators on the Maserati engines with many rotations to dial in correctly.
There are no short cuts and you don't want disturbing that's for sure.
Miss those days.
Thanks for sharing and I hope you video the start up as that's the Best bit.
 

Bebs

Member
Messages
3,265
I will ask AV Engineering to film the initial start up, good idea!
Still a way to go until we get there. A lot of work is being carried out in and around the engine bay.
The heat shields are being resurfaced etc.
 

philw696

Member
Messages
25,113
I will ask AV Engineering to film the initial start up, good idea!
Still a way to go until we get there. A lot of work is being carried out in and around the engine bay.
The heat shields are being resurfaced etc.
I'm sure AV had that planned anyway.
Certainly appreciate how much work is involved for sure as a Technician but it's always nice to know the owner does too.
 

Bebs

Member
Messages
3,265
I'm sure AV had that planned anyway.
Certainly appreciate how much work is involved for sure as a Technician but it's always nice to know the owner does too.
I try to engage as much as possible although I’m no Techy. Very pleasing to receive updates with photos on a regular basis.
 

Bebs

Member
Messages
3,265
AV Engineering have now turned their attention to the gearbox. I felt it was worth spending some hours taking the cassette out of the casing and having a good look around given the mileage it has covered.
When the gearbox was inspected originally on removal, Aldous found a slight oil leak from the plug. Now that it’s apart it has become apparent that somebody, at some stage, have over torqued the plug, destroying the thread.. old silicone was smothered all around it in an attempt to seal it.
You can see on the photo below how the plug actually sits at an angle because of the destroyed thread!
6430964310
 

Bebs

Member
Messages
3,265
The correct solution is to try and helicoil a new thread into the casing and AV are now attempting to do just that.
In terms of the actual gear cassette itself, it is apparently in remarkably good condition given the 105,000 miles and requires nothing! Phew! Clearly ‘one careful owner’ :)
The casing will be cleaned up completely and once helicoil’ed, the cassette will be reinserted and6431164312643136431464315 we’re good to go.
 

Lavazza

Member
Messages
1,060
Another great update, but must be disappointing to learn of poor practice at earlier services, presumably by 'specialists'.
Makes you wonder who you can trust.
This thread is a really great advert for AV's professionalism though, and your care as a custodian of your F360.
 

Oneball

Member
Messages
11,071
Synchros and gears, look in great condition for 100k, someone has been driving very well.
 

Bebs

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3,265
Another great update, but must be disappointing to learn of poor practice at earlier services, presumably by 'specialists'.
Makes you wonder who you can trust.
This thread is a really great advert for AV's professionalism though, and your care as a custodian of your F360.
Thank you Lavazza, very kind words.
In addition to all the photos from AV I always receive a video as well with full tutorial of the various issues etc. Complete transparency from AV, something that is pretty rare these days.
I suspect the same specialist that fitted the wrong rear main seal also over torqued the plug..
 

philw696

Member
Messages
25,113
As the others have said Great Work from AV and Team and what a record of all the work being done.