Engine and engine auxiliaries repair

Usable engine components were prepared for assembling.

Prior to mechanical treatment of the engine head remnants of the broken threaded studs were removed.

Engine head was prepared for following grinding of the surface facing the block and machining of the valve seats.

Arrived first of parts consignments with components mainly for engine assembling.

Air filter housing was assembled using restored parts.

Engine hood opening wire control was prepared for assembling.

Water pump was assembled using restored and new parts.

Restored throttle was pre-assembled.

Restored injection system was assembled onto the inlet manifold.

Cold start valve was installed on the inlet manifold.

Fuel filter and vibration dampers assembling unit was preassembled.

Cooling system pump was prepared for installation on to the engine.

Head was received for assembling from machining workshop.

New and restored components were used for distributor drive assembling.

Arrived cargo with parts required for repair of the engine.

Prepared engine block was sent to powder coating.

Engine components were prepared for assembling.

As crankshaft was received from machining, we started preparations for assembling of the engine.

After machining engine block was installed onto engine assembling rig.

We managed to source new pistons and front suspension components.

Restored engine head was attached to the block.

Injection pump was attached to the engine block.

Some of cooling system alloy components had corrosion damages. Holes were plugged by welding before installation.

Heat insulation plate of the intake manifold was damaged.

We restored aluminium layer of the heat shield and prepared it for installation.

Water pump and all related components were attached to the engine block.

Restored fuel supply unit with filter and flow dampers was installed.

We installed fuel injectors and distributors.

We reproduced a copy of missing manifold support strut.

Several missing engine components were reproduced as copies of available original parts.

We installed all ancillaries onto the engine before tests.

We manufactured anew all pipes and hoses connecting engine ancillaries.

We installed and interconnected fuel supply and ignition system components.

As engine was removed from assembling rig, clutch components were installed in place.

We installed preassembled engine onto the test rig.

Renovated alternator and voltage regulator were connected for tests.

Restored dashboard gauges were connected to the engine for tests.

We installed and connected to the cooling system restored heater unit.

Gearbox was installed for the operational tests.

All required liquids were filled up for the tests.

Engine was started and initial adjustments were carried out.

We used for the tests equipment providing highest possible accuracy.

We finished our test session adjusting necessary CO level.

Restored engine was tuned on our test rig.

We checked and repaired before installation on the test rig all involved electrical components.

We completed assessment of the completely restored system and performed needed adjustments of performance parameters.

After tests engine was removed from the test rig and stored until assembling of the car.

Fuel tank was completely disassembled for inspection and repair.

Fuel had been melted mesh of the strainer so we had to replace it.

New fuel pump base plate and protection screen were self-manufactured.

Fuel pump assembling unit was prepared for installation.

Cab heater pipe was completely damaged by corrosion so we had to self-manufacture replacement.

Re-created pipe was sent to powder coating before installation.

We produced missing accelerator pedal installation bracket.

Correct for our model accelerator leaver was self-manufactured.

New wiring harness was placed into the body.

New power cables were self-manufactured.

New power cables were installed into engine compartment.

Engine compartment electrical appliances were connected to the new wiring harness.