1991 480 ES "Williams" 2.0 16v conversion!

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cranna21
Knows an Aerodeck isn't a 480
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Location: Aberdeenshire, Huntly

Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by cranna21 » Mon Nov 04, 2019 9:59 am

Gather round kids and grab your popcorn for a story of 'not high enough oil pressure' based woe!

SO.

after spending £50 on some fancy drill bits to remove the 16/21 remaining buggered torx bits bolding the sump on (for anyone interested Milwaukee's new shockwave impact drill bits are fantastic) I was greeted to a lovely silvery mist in the sump along with a few larger particles... deep joy

upon removing the oil pump in the F7R and getting in about to the connecting rods it was evident that they were WAAAY out of spec as far as side play goes, and further to this, the crank had too much end float also - :wall: :wall:

fast forward a few hours and the pistons and rods are all out, crank removed also. The engine's been rebuilt in the past to a less than perfect standard it seems, looks as though someones took a shortcut with the thrust washers on the crank and let the crank wander too much causing ware to the actual crank! not just the bearings! Found a few shards of bearing along the way floating around...

So new plan, rebuild the lot, I have a spare of everything, so spare crank will be sent out to be prepped for a rebuild along with spare block, then I think I'm going for a forged 11.5:1 compression ratio piston and rod set up, coupled with as good bearings as I can get throughout as well as fasteners.

see below pics!

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'91 480 ES 2.0l 16v 'Williams' Conversion - 208bhp/230nm
'91 940 GL 2.0l Estate
'09 C30 2.0d R-Design

jifflemon
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Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by jifflemon » Mon Nov 04, 2019 12:05 pm

Holy cow.... :badmood:

Still, do it once, do it right. At least you'll have way more faith in the engine. Am amazing the thing wasn't knocking itself to the death!

Alan 480
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Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by Alan 480 » Mon Nov 04, 2019 12:51 pm

not liking the sight of the divots of 'shiney metal' :-(
Alan

480 ES 2litre x 2, C30 1.8ES, SS1

cranna21
Knows an Aerodeck isn't a 480
Posts: 253
Joined: Sat Jan 11, 2014 3:44 pm
Location: Aberdeenshire, Huntly

Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by cranna21 » Mon Nov 04, 2019 1:24 pm

Noooo never the nicest sight on a Saturday morning!

it seems my spare crank isn't actually what it's supposed to me and is for a later engine with a chain-driven oil pump, supposedly the "do work" but not taking the chances.

I've managed to source and buy a replacement Clio Williams crank from a slightly not that well spoken of firm in Birmingham but I'm sure PayPal and eBay buyers protection will do its thing if it all goes pear shape - will get the new crank up to my local machine shop of choice for a check over!
'91 480 ES 2.0l 16v 'Williams' Conversion - 208bhp/230nm
'91 940 GL 2.0l Estate
'09 C30 2.0d R-Design

jifflemon
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Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by jifflemon » Mon Nov 04, 2019 2:06 pm

Think you could get the block bored to 84mm.....

You know, as you're replacing the pistons already.....

cranna21
Knows an Aerodeck isn't a 480
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Location: Aberdeenshire, Huntly

Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by cranna21 » Mon Nov 04, 2019 2:44 pm

I might have a spare block but i'd rather not waste one by splitting cylinder walls! haha plus i have a £140 athena MLS head gasket here for standard bore because the head was off away getting done anyway, so will have to pick the best block and get it honed and fire on!
'91 480 ES 2.0l 16v 'Williams' Conversion - 208bhp/230nm
'91 940 GL 2.0l Estate
'09 C30 2.0d R-Design

cranna21
Knows an Aerodeck isn't a 480
Posts: 253
Joined: Sat Jan 11, 2014 3:44 pm
Location: Aberdeenshire, Huntly

Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by cranna21 » Tue Nov 05, 2019 11:12 am

Block Number 2 (which coincidently was actually the first Williams engine I bought) has been pulled out of storage.

This block was all nicely honed and painted with new oil pump bearings pressed in before I ended up buying the second engine in 2018 (the one that has just gone pop!) upon inspection it's going to need a re-hone at the very least as with sitting a little bit of condensation flash corrosion has hit tiny parts of the bores - having said that it needs a little bit of a bore-out anyway!

I've been sent the specs for the pistons I'm planning on buying for getting the bores done so that bit of leg work is done and I'll get the block and replacement crank up to get all checked out and any work needing done completed ASAP!
'91 480 ES 2.0l 16v 'Williams' Conversion - 208bhp/230nm
'91 940 GL 2.0l Estate
'09 C30 2.0d R-Design

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JohnTurbo
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Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by JohnTurbo » Tue Nov 05, 2019 11:58 am

I like this very much. Good luck with the new engine!

Were compatable mounts available? Drive shafts?

John
Past:
94 Turbo - Red
94 Turbo - Black (Converted from NA 2.0)
92 Turbo - Red
90 Turbo - Silver
Now:
00 Exige
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cranna21
Knows an Aerodeck isn't a 480
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Joined: Sat Jan 11, 2014 3:44 pm
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Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by cranna21 » Tue Nov 05, 2019 12:09 pm

All standard sir - bolting it in has so far been the only straightforward part :lol:
'91 480 ES 2.0l 16v 'Williams' Conversion - 208bhp/230nm
'91 940 GL 2.0l Estate
'09 C30 2.0d R-Design

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Murf
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Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by Murf » Thu Nov 07, 2019 10:20 am

You may as well get forged internals and fit a turbo while you have it all in bits 😁
Kia Pro'ceed GT 1.6 Turbo
1992 480 Turbo
S40 shitheap for winter commuting 🙈
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cranna21
Knows an Aerodeck isn't a 480
Posts: 253
Joined: Sat Jan 11, 2014 3:44 pm
Location: Aberdeenshire, Huntly

Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by cranna21 » Thu Nov 14, 2019 2:57 pm

Replacement reconditioned crank arrived about a week ago, sent away to get dimensionally checked and came back perfect so new KING Racing bearings are here for the bottom end in standard sizes along with ARP main bearing studs and hardware!

Waiting on the block being bored/honed and head to be rebuilt and I can get some pistons ordered! :)

Interestingly enough one of the exhaust valves was about ready to fire itself into the cylinder anyway! pics attached!

Image

Image
'91 480 ES 2.0l 16v 'Williams' Conversion - 208bhp/230nm
'91 940 GL 2.0l Estate
'09 C30 2.0d R-Design

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brinkie
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Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by brinkie » Thu Nov 14, 2019 3:14 pm

close call. :shock:
Robert.

Present cars: 1994 Volvo 480 GT 2.0i Vase Green, 2010 Volvo V70 2.0F Momentum Mystic Silver
Past: 1981 Talbot-Matra Murena 2.2 Rouge Mephisto, 1995 Volvo 480 GT 2.0i Paris Blue

jifflemon
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Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by jifflemon » Thu Nov 14, 2019 3:30 pm

that's incredible!

It would appear the entire engine was one good rev away from becoming a grenade!

Hopefully you feel better about taking it apart now?

cranna21
Knows an Aerodeck isn't a 480
Posts: 253
Joined: Sat Jan 11, 2014 3:44 pm
Location: Aberdeenshire, Huntly

Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by cranna21 » Thu Nov 14, 2019 3:46 pm

I'm more than happy i took it apart now! :rofl:

watch this space though... I've decided to go a bit daft... ;)
'91 480 ES 2.0l 16v 'Williams' Conversion - 208bhp/230nm
'91 940 GL 2.0l Estate
'09 C30 2.0d R-Design

Alan 480
480 Is my middle name
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Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by Alan 480 » Fri Nov 15, 2019 12:46 pm

cranna21 wrote:
Thu Nov 14, 2019 3:46 pm
I'm more than happy i took it apart now! :rofl:

watch this space though... I've decided to go a bit daft... ;)
200+ BHP nae enuf :D

you will need a LSD pretty soon, or four wheel drive, now that's daft
Alan

480 ES 2litre x 2, C30 1.8ES, SS1

cranna21
Knows an Aerodeck isn't a 480
Posts: 253
Joined: Sat Jan 11, 2014 3:44 pm
Location: Aberdeenshire, Huntly

Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by cranna21 » Fri Nov 15, 2019 1:41 pm

yeah safe to say I'll definitely be pushing boundaries of not having an LSD!
'91 480 ES 2.0l 16v 'Williams' Conversion - 208bhp/230nm
'91 940 GL 2.0l Estate
'09 C30 2.0d R-Design

Alan 480
480 Is my middle name
Posts: 1064
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by Alan 480 » Fri Nov 15, 2019 5:51 pm

cranna21 wrote:
Fri Nov 15, 2019 1:41 pm
yeah safe to say I'll definitely be pushing boundaries of not having an LSD!
they are here, if you have few ££ to spare :shock:

https://shop.quaife.co.uk/renault-5-gt- ... fferential


but you might get one from a Clio that has already been wrapped around a tree/lamp post??? ;)
Alan

480 ES 2litre x 2, C30 1.8ES, SS1

cranna21
Knows an Aerodeck isn't a 480
Posts: 253
Joined: Sat Jan 11, 2014 3:44 pm
Location: Aberdeenshire, Huntly

Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by cranna21 » Mon Nov 18, 2019 12:49 pm

aye they're not cheap!!! one day maybe haha
'91 480 ES 2.0l 16v 'Williams' Conversion - 208bhp/230nm
'91 940 GL 2.0l Estate
'09 C30 2.0d R-Design

cranna21
Knows an Aerodeck isn't a 480
Posts: 253
Joined: Sat Jan 11, 2014 3:44 pm
Location: Aberdeenshire, Huntly

Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by cranna21 » Fri Dec 20, 2019 1:26 pm

Well folks, unfortunately, no pictures to update you all with at the moment as it's all been a bit slow recently!

With assuming my role as backstage manager for a local Panto at the end of November and beginning of December all of my time was eaten up! And just as I was away to make the big order of my new pistons my daily driver C30 has decided it wants a new flywheel... so between that and its MOT the 480 will have to be put to the weigh side for a few weeks again till the funds are built back up...

On the plus side, I now have a crank, Block and head all ready to go and I have all the new bearings and gaskets sitting in the wings waiting, so just pistons to go!

In the meantime I'm playing with wiring, I'm re-routing the engine and engine bay looms to come through the inner wings and clear up a little bit of clutter in the engine bay, amazingly little to no wires will need extending! it all fits! A little bit of a time-consuming task but oddly satisfying.

Hopefully, I can upload some exciting pics and news soon and of course, hope everyone has a great festive season :)
'91 480 ES 2.0l 16v 'Williams' Conversion - 208bhp/230nm
'91 940 GL 2.0l Estate
'09 C30 2.0d R-Design

cranna21
Knows an Aerodeck isn't a 480
Posts: 253
Joined: Sat Jan 11, 2014 3:44 pm
Location: Aberdeenshire, Huntly

Re: 1991 480 ES "Williams" 2.0 16v conversion!

Post by cranna21 » Mon Jan 06, 2020 3:44 pm

Well... after the stress of incorrect parts being supplied for the clutch + flywheel for the C30 my 940 can be put back into semi-retirement for winter and the C30 back into daily duties! MOT on the C30 due next week and all looks reasonably well on it so fingers crossed...

see pics of the C30 + 940 attached in case you're interested! :)

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In other news, I've taken the plunge and ordered my pistons for Williams engine - some 11.2:1 83mm forged pistons with forged H beam rods to match along with associated hardware! Hopefully here soon, been a while since I've had some nice shiny bits for the 480!
'91 480 ES 2.0l 16v 'Williams' Conversion - 208bhp/230nm
'91 940 GL 2.0l Estate
'09 C30 2.0d R-Design

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