Clementine's Garage
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Yellow R4
 
Réparateur d'automobiles

R4 GTL 1985 Restoration

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
Again a few pictures about dismantling the engine.

The oil pump is later to be further disassembled and cleaned.
y4maBgk9C-7J_0Tt_oiXreKgHjxDfU9AfDCln-oBchDBlrKDxVrUevtMxOPFjjxqsm64mjTYccyMHqrW9hTqN8Q16-pBsx4ctCz2tK0nBZHrvJk_hCoPMIWRX3EF-o8A4XBpIugGwhSTn-gaBoPNZZyJP1A1EGnawZxf2bnYp7zezVcbjNQs6-I7kgQSb7noRavAQkAH90gXzraMhknM9Ya6A


A peek behind camshaft sprocket. Chain and sprockets look good, usually go with 500,000 km (312500 mi) before having to be replaced.
y4mnxoxOlm0rzwyRqd3ZWUcNClVDV8d6sEqzWHQX8qaX6cbbKtIfNw_9kcU9lqjBha8jMlTE3sHCmMIx8e8jtUE3GIGRJj398rmAVsQIH4ty7KpbYVs5QAt6MbZ8DkuyBYOSZpzuGcoSRuzqMzDC0Omir_CBpFZ5hdXfqmC0Cgk1IHB3XAZ9yxcmjoNg6aI9MmCR6_POq-3_3YwOvQj9NNwBg


Removing the camshaft, first remove the distributor shaft (which is very easy on Cleon type engines)

y4mFnL_iCAWy3-6qu7kVmPsDNFe1SWOOJmSAskvwf6SmacovWqvSyGLiFQ30afxKNQpbEvJhwaWgY3Ine7nk96ASqPeZLWG07fQ0Gk01MLTqFHZ5CG1OhZ7kD5RubMMsRowYflHHLkm24AYWubV7igmC1EbBS2gPyd9xoELwUDOuClXrflkxUhx2hUdoiqZozuf3NLO1LduQVETO1pORlckKw


A peek on the crankshaft.
y4mqfcDdkIXsQ48KBHBFU3pmCv1YTA0As8OmqIUHjQUtJDKnnZY4rcnsBNvVdG1CqeX13X4W9cowCL1aG17vF9sROebVzpJiDkj_M4m8wOJ6lLtLpv3PCdH9BV1-AlC-qGgT5Nk_F79fvLUWSLbPagDThq1vEZNrZ47V6tXTCV4OC9_fuIitI_GvC5UCgOsQvWaEi9k4r1nshbYSVZMbdM2pA


Connecting rod bearings on piston No. 1.
y4mUZRjvwpZVrAIKRxMnWQpMRKzRkZrWwAGJBJzwIYakQCPg-EwjYA3e45-ChMefd8DSE2qj9OPvaFXnkfBtsK--yyz43c80q2QWIrRwftZdfrIctV1-4Vr5UgI2Z8bOI3H3P0veVpRyOPPEjmjToWFg_olfB0bmHRu-qQCH_d-yk1XHJnzmwr0xFwLwnV-rZqYxtIXuFc_Z9lujMTLrZVDPQ


Extracting the piston with its liner.
y4mtvffo-JjQtwkLl6627hD9H4KzX4JRAyASaG34gLfxtey9oZ3Np8951sFnuqHOu3ocJ735U_ZuhZGoKsInMM7-8K9OcDdQuDsFzILbx7X03HeOn4zibmufX2wMkZ5B8Y8-XLaCRyUZGWN-IbiKn9O9rIEJKnvDxyFfUOJ051bYS2KVHX2n0tkZavG15MCMfyHsWozTt-DcBiP-0OJhQz7BA


Keep everything on sequence and to each other.
y4mALuQtTOD0n4A8p7HcinAGzW4j60o7nKPuPGFssdg80wsUM1fpe8CtAmizOUs7gegA_WKiaRCt7vCrJJKVINzr5Lkt_jYpHOVaZtPCUVurbkILR8XLp5aSkAVH5iYykg6B197-smoOVKOzFqf7XoPmiLeVfXq13nlJg6WZHe07jAndbX58ScUqwpAr_mSiFwF-aUYaAkdx22OojUw95ArRw


17 bhp left :dontknow:
y4mE6pmHh0AdtQxqnfvRNYU9krh6J2eD8U7_MmDIqXwv06Kw7Qz-dSp0eJHQmgh4aP2GY63ldDPdNfXLQDYNM7wsOy_LGWITW58ExlctS6mVNTjkmOdS-pPz2fHkBBZnmwCFfwuRBd5N2VAeR_zQ8wPt_QzfQHF7kAjTJZQJML2lI58Hbhl8jAcQP8MrjgJuOmVnJIAWOdZRTZWzhV2bYowMA


And finally the connecting rod bearings on piston No. 4.
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A peek at the connecting rod faces on the crankshaft and decided it will get a grinding and polishing turn.
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y4mBcPVVbKFaLBVrrUHnRMAbFGiJLWHtyBj2m6rGfJaJPE4GoM4847fHVBtOYWUAMKTfqs_dwsdyyA4dg4a_8KeidpGNL7vJCB8NrgjQireW5a6EqaimDWX0VpYtSOdx4Zf_51JbZFoD0fOqJlG61YpmkBqLJfPSGyPxn1YAfTlyXY2znWDQ_a6aVFfs-Z4YpVxxH6gi7lK1JHHPxxMKLULfQ


Cleaning job No. 1001
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Crankshaft bearings removed and taken out.
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Last edited:

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
With an old clamp and homebrew welded tool you can screw and detach valve springs.
y4mpJcIc5KMBDox6wv_7Sbwh-4yyubPkVPtEMmisHBkevqYTCxxpQ9NVEEAYonvdj9EModbAKXo3oxGOeoP2NZYdz9BFuxMPydSX0mEkWyuNXB9j4H91kNcUwdCvi896DlexZrOJc9XvmEok5r3hn7gCiO3bnDGL1WKzh8dV90gDDQaZaixvI2cVaq9m7MRCFijeZNNP2Pf7e8h_Hyfip7kiQ


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Little carbon deposits but otherwise just fine.
y4m737edygZm0bJLAdq5Ciusrh-R55LgnbHUtusUfw2JxMK20BCps6Il_arZRgCN-s5mt-FNBVJzDYs6wXf_045eC8uVHgcPFhcfMfOQ5WtBTOAJDymDVxfgWFqUfqoXIh8iLBMGNjJ0mHrVmV3_eZHu5k9aXkDvJVMcW97nCRvhw9URep_C9_W-bCpiMja5R55EdTQZ2ud6hUXw26Mq7WzAw


Again, keep everything on sequence and to each other.
y4mxk2pZDeXM9dw9GFxYYqx24Bhl2zsDTuCIk1Abf8tXeDq5K-npIIb6xDoJN8gnib4iam9LWmkm4zqg8V9MmKKypiqBGdR3gGbv4-jWiL5irloYFG6iFC6LOI3MiYG91fE5FIfzmC8HKXFCDl0_k8PuS2DqWQgCLQm7hfdfyNWUcWYdLauz-NYRC_8_tjGorM7Em5hFeU9HV31iIBmax-3Bw


A peek on the cylinder head and cleaning job No. (I lost count) :confused:
y4mg86SHoeP4rzA781XEm4jQEXqe1157LKWySfEn25nme-BdWo_eJG9so29t8jYYsWx3tp3KmRQ8vSA6RlAxyLlFdQ4NiPNGSPvxxR6M3JP-8p_j5n0SekXda4NIa-Vp8TjQxnfnDBuLOyLb8puiRywkqe5d2pn4NpwAoAlvqzHYz7-8DMZONVPqKBwXWkut0lDSupeCVl_mMrrGCzxStU-4A



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Funny that the oil pressure sensor always did his job, given the sludge ...
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When previously draining the coolant, nothing came out of the engine drain plug.
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Only now you can easily see why not, a nice accumulation of stuff called ...
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Meanwhile I received some repair material.
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I'll have to wait for some first welding, untill I get my hands on a chassis jig from one of the dutch forum members.
For now I will get my hands dirty on cleaning and soda blasting all of the engine parts, as well as ordering new bearings, seals and so on.
This will keep me and my son busy for weeks :whistle:
 
Last edited:

Jurjenz

Enthusiast
Messages
447
Location
Groningen, Netherlands
Wow, it can definately use a good cleaning and it is going to be very rewarding! Can't wait to see a next update, keep it up! :waving:
 

JonathanT

Not normal for Norfolk
Messages
1,324
Location
Wymondham Norfolk
With an old clamp and homebrew welded tool you can screw and detach valve springs.
072_zpsit0zfboc.jpg




073_zpsbrbmt7qx.jpg


Little carbon deposits but otherwise just fine as well as the valve guides.
074_zpskhcoqgkk.jpg


Again, keep everything on sequence and to each other.
075_zpsli6vi5ye.jpg


A peek on the cylinder head and cleaning job No. (I lost count) :confused:
076_zpsg82mttl7.jpg




077_zps06gtwcyq.jpg


Funny that the oil pressure sensor always did his job, given the sludge ...
080_zpsyccoe6td.jpg


When previously draining the coolant, nothing came out of the engine drain plug.
081_zpsvbuaumyp.jpg



Only now you can easily see why not, a nice accumulation of stuff called ...
082_zps8yfdnyhs.jpg



Meanwhile I received some repair material.
084_zpsbk0fg41e.jpg



I'll have to wait for some first welding, untill I get my hands on a chassis jig from one of the dutch forum members.
For now I will get my hands dirty on cleaning and soda blasting all of the engine parts, as well as ordering new bearings, seals and so on.
This will keep me and my son busy for weeks :whistle:
Thats a great descision with the complete rear chassis leg replacement. I was wondering how you would check the alignment following complete removal. A chassis jig would solve that
 

petak

Enthusiast
Messages
1,756
Location
Vodice, Croatia
pictures, pictures and writing down every step of the way is crucial thing to do if you want your car back again :D

I have full booklet drawing, measurements, and steps how to.......just in case.....

I did not have timeframe for the job and took me 5 and half years to do it.....aldo i could not buy every chassis parts but had to made it on my own.

It is good to have new car and project on the forum.

will follow your progress
 

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
And now for something completely different...
The last couple of weeks I couldn't spent time on the R4 restoration, I was held up by a major domestic restoration as there was a water leakage in my kitchen and the whole oak wooden floor came to life :(.
So I made a decision to completely replace the 22mm full oak wooden floor for marble floor tiles.
 
Last edited:

JonathanT

Not normal for Norfolk
Messages
1,324
Location
Wymondham Norfolk
And now for something completely different...
The last couple of weeks I couldn't spent time on the R4 restoration, I was held up by a major domestic restoration as there was a water leakage in my kitchen and the whole oak wooden floor came to life :(.
So I made a decision to completely replace the 22mm full oak wooden floor for marble floor tiles.

Found the source.
01_zpsd5kb25wi.jpg


And the cause.
02_zpsfpbx4box.jpg


Remove old floor.
03_zpsmo6trhbs.jpg


The dog is helpfull as ever, especially defending his favorite spot the wood stove. :D
04_zpsdlzo41vl.jpg


The floor layout.
05_zps5bhhxbhb.jpg


Adding some benefits.
06_zpspysabh45.jpg


Almost done.
07_zpshkmxukm0.jpg


Grouting.
08_zpsa8efmh0l.jpg


And done :p
09_zpsgty76dsa.jpg
Nice Job!
 

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
Thanks Jonathan, but I'd rather have greasy hands than hurting my knees on doing some masonry :laughing:
 

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
It is not always good thing to have many skils :D like you do have.
:drunk:
I know but all my mothers and both son in laws really are all thumbs, so I've got many households to maintain in DIY.
But extra help is on it's way as my oldest son is in training for Carpenter :) and the youngest son a megatronica student :cool:
 

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
Spring has started and after spending too much time in household DIY's, it's now time to get things going on the R4

This means cleaning and cleaning... it's spring-cleaning time after all ;)
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As I mentioned earlier, spark-plug no. 2 was out of allignment. After cleaning it appears the thread had been refurbished and replaced. Luckely NOT a terrible heli- or v-coil.
y4mP-WrPnlmx_0IQkS6JdCC1RCB895ap4Mgn0MMPSvzFq0P3-ju-oGaz4IrET9rdvMaZUH4zUnbYmIgn7o9h5g-yiPA98J1oU0XrQnjO3K2Hv4sjqvBxtt776mUv5IdqY65spRx1R2yiMypp-cg7n84dsJBgJ4TCpkbufb6Y7s3vYmhvgiN_SxVfjR-cJS0f3zkBjGPIz1hIIWE3R3BozCRMQ


More spring-cleaning...
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To get rid of all the black sludge I decided to seperate the innerpart from the valve cover.
y4mP_WGTmejsgUhanZDGJgtKI8XmUJS94XDW_dK2GXhHBcKdiD99Mk_kS-QUu19N5aB2jWhlRPat2TEsdRF-dADkQ44yz2j6EyUD7HOy1Gz6IckLlGFdcxKNw2Qfcb5xJL-Q5vrNFpbn9mhpBdWOZWIhQEQ7VPljT_m4agUEyNhLKOV1eLQQfHhA0JH5xelvHRsF8zAWjWjtRwLcW7ecQ5AqQ


After a cleanjob I welded it together on 12 points.
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Last edited:

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
Sanding, priming, sanding, filling, sanding, priming, sanding, painting, painting, sanding, painting, painting, painting, sanding, painting, painting, painting, painting, sanding, painting ...
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:waving:
 
Last edited:

Jurjenz

Enthusiast
Messages
447
Location
Groningen, Netherlands
Wow, lovely progress! Good choise to clean the valve cover. Keep it up!
 

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
And further and further we go and with the weather it's also going the right way.

Grinding valve seats,
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and don't forget to grind the feet of the cylinder bushes.
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Result before and after grinding so the cylinder foot seals will properly fit.
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New springs for the pistons.
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Piston and cylinder bush are reunited by means of a pushing piston compressor,
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and with some motivation of a soft hammer, reunification is a fact.
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Cozy the 4 of them, ready for their 34 BHP (24.981636 kW).
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The various seals, the choice is huge.
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Gently place gasket and then measure.
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Of course, the gap (clearance) is determined with a measuring instrument so that it is within their tolerance.
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Place and secure cylinder bushes, pay attention to Arrow at the top of each piston, pointing to flywheel side.
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Everything placed, measured and secured.
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Turn the block a bit and continue with work on the underside.
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Placed new bearings.
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Placed the crankshaft.
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Placed the crankshaftcaps and conrod caps with their bearings.
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The crankshaft bolts and conrod nuts get their own moment.
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And then....
 
Last edited:

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
Aaaarrgghhh, a small disaster.
Of course, there's always a bolt that will fail during a massive 40Nm of violence.
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It's only 1 but I replace all conrod bolts and nuts.
Can't live with the idea that one or more of the remaining 7 old bolts suddenly collapse under metal fatigue in a near future. Don't dare to play with Murphy's law :D
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Fortunately, there is still enough NOS to be found, if you are patient and keep searching.
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All 4 connecting rods are fitted with their NOS-parts and also fitted the oil pump.
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The camshaft is in turn,
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sprocket placed and set the timing,
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timing chain and tensioner in place.
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With the correct position of drive shaft for the distributor you need to be patient.
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New head gasket.
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With the well-known home, garden and kitchen tools, the valves are returned.
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Everything is getting shape again.
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Rockers added.
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Torque wrenching nuts and bolts.
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The cylinder head bolts get their first moment, they will be treated in the future.
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More to come, next time :waving:
 
Last edited:

JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
Again a small update.
The work consists of cleaning and revision of various components. The water pump has been done and the original Ducellier generator was already been revised at Valeo.

I also found out that the installed distributor originated from a R5, and a R5 isn't a R4.
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Fortunately I found an original Ducellier R4 distributor and gave it a well deserved cleaning.
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Ready for assembly.
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The original Ducellier starter engine is in turn.
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Small exploded view.
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The stator is kindly contaminated with some wear of the copper brushes.
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Give it a cleansing.
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The rotor also didn't look that fresh anymore.
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Give it a cleansing.
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The outer parts receive a layer of primer,
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and slowly they regain color again.
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Ready for assembly.
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JdeW

Enthusiast
Messages
699
Location
Laarbeek The Netherlands
A look around the gearbox ....
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Disassembling which makes it easier to clean.
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No words....
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Upper lid and a peek in the gear case.
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The front cover is also excused.
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After a few hours we see again that the lids truly are made from aluminum and the cap of the vent valve is really original blue.
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Next time more progress, for now I have a long weekend holiday. :waving:
 
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