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KDS Keltec Ferrari F355 GTS Restoration Part Three

8K views 7 replies 6 participants last post by  James_R 
#1 · (Edited)
Hi Guys,

I thought I make the most of this strange situation/opportunity while we are all in the coronavirus lockdown to compile the Very comprehensive Ferrari F355 thread.

This thread will be a very long in-depth thread of the full restoration that we carried out a few years back on this Ferrari F355 GTS.
Hopefully will help with those detailing blues and kill a few hours while reading through it too.

PART THREE the mechanical work on the engine.

With the engine removed it was time to address all the servicing and cosmetics
The process started with the throttle bodies.






Here are the after photos of the throttle bodies all cleaned.





The Ferrari HT leads can break if incorrectly pulled on. There is a special tool for just a job.



Once the plug leads are off.



We can remove the rocker cover boxes to reveal the camshafts which is critical to check cam timing



We found many confusing tipex marks from past cambelt changes, now the engine ran entirely without fault and gave me no suspicions of incorrect timing, but it was worth checking while the engine was out.








Before removing cam pulley wheels, It was time to replace the water pump.







Water pump replaced it was onto the oil seals replacement and cam timing check.









The camshaft running faces for the oil seals was cleaned up with very fine sandpaper.



Much better afterwards



The oil seals were pushed into the housing using a driver set.








After fitting the oil seal housing, it was into the cam wheels fitments on the camshafts, this means we could rotate the cams to align them up with markers on the alloy housing.






To obtain exact Top dead centre, I use this method.
A long bar with a marker and then rotate and stop before top dead centre.




Then rotate in the opposite direction and mark the front crank pulley like this





Divide the 2 marks equally





Now I have a true top dead centre



Now I can align the camshafts with there associated alignment marks.

On this particular engine its trial and error of removing the cam wheels and refitting them while holding the camshafts perfectly aligned.

Notice the cam wheel has equally spaced dowl holes.




And the camshaft has unequal holes.



This means a fine-tuning of timing is achieved by placement (alignment) of the two holes with the fixing dowl.

Once everything was aligned including the crankshaft sensor.




It was time to fit up the freshly painted in house rocker cover boxes, but first, install the seal around sparkplug holes and then the gaskets.





I tiny bit of seal glue was used to hold the small o rings in place, this glue is a none hardening glue type.




Engine all timed and tensioned up it was time to install the spark plugs








Notice the cambelts don't connect directly to the crankshaft?
The crank has a gear drive inside the block that connects to the two lower cambelt drives,
this engine is a true flat-plane crank and runs as two 4 cylinders with the shared crankshaft,
which gives it such s distinctive lovely sound and high revving engine.




This also gave Ferrari the chance to alter the gear ratio of the drive which meant it could run very small camshaft pulleys.
all helping to design and build a small compact engine with an extremely low centre of gravity, also added by dry-sump system.









The last thing to address now the engine is all sealed up was air and water pipes.












New pipes and clips install throughout the engine to finish it off.

That concludes part three the engine mechanical section.



Many thanks for reading any question, fire away.

Part One is found https://www.detailingworld.co.uk/forum/showthread.php?t=419835

Part Two is found https://www.detailingworld.co.uk/forum/showthread.php?t=419841

Part Three is found https://www.detailingworld.co.uk/forum/showthread.php?t=420020

Part Four is found https://www.detailingworld.co.uk/forum/showthread.php?t=420272

Regards Kelly Harris

Website - www.kdskeltec.co.uk

Youtube - https://www.youtube.com/user/kdskeltectv

Facebook - https://www.facebook.com/KDSKeltec

Instagram - https://www.instagram.com/kdskeltec/
 
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#7 ·
next chapter is up live and writing chapter 5 right now

I saw that throttle body and shouted WTF, How TF.

Absolutely incredible work, you are the Jedi master of your numerous Trades. Jack of no trades, master of all it seems.

Looking forward to the other 7-17 sections
Another fantastic read, thanks for sharing :thumb:
thanks guys

Lovely work again Kelly

Did you repaint the crackle finish red on the rocker covers in house ?

They look great
Yes all in house, not a part of this restoration left the KDS workshop.

Kelly
 
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