Club G40 Forum
Club G40 => Photos and videos => Ongoing Projects => Topic started by: AdzCM on March 12, 2014, 11:47:05 am
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The history......
Bought my G40 just over 4 years ago, completely standard in capri green. The initial journey to pick it up from just outside London was a story in itself.
Anyway, had no idea if the car was going be a heap or a winner. Turned out to be a winner :) - drove the car from London to Holyhead - then Dublin to nearly the Top of Northern Ireland using nearly 2 tanks of fuel, driving nearly 600miles, and many 120mph bursts [to make the ferry, which we did....just] all the while, it didn't miss a beat. If that wasn’t a test for the engine, I don’t know what is…
Unfortunately I have no pictures anymore of the polo in its standard form :( so this build thread is off to a great start haha...
Shortly after getting the car home, I signed up to this forum and it was the best decision I made in Polo terms. The help and advice has been brilliant because to be honest, I didn’t know a terrible amount about the G40. Some of my earlier posts are embarrassing to say the least haha, but you have to start somewhere
After staring at the forum for countless months, I found out about ported chargers and 65mm pulleys – so bought a fully rebuilt, ported [full blend] charger and got a 65mm pulley/chip – completely transformed the car. The only problem was the need for sticky belt dressing which covered the engine bay…nasty.
Also did the boost return mod, added a 51mm throttle body, a GT inlet manifold and fitted new coil-overs with new steel wheels [195/45/14] as well as a few other minor things.
Ran that setup for quite a while and thought about toothed pulleys, but decided to go the turbo route instead. The cap on power the charger can provide was a put off as well as the need for 20k rebuilds on the 65mm pulley. Turbo route had more advantages in my opinion.
So from memory I bought all the following parts for the turbo setup:
- K03 turbo
- Manifold
- Downpipe
- Oil feed/drain
- Water cooling pipes for turbo
- Sump with turbo oil drain
- 268 Camshaft
- 6psi boost switch
- Cg Motorsport Kevlar clutch
- Universal front mounted intercooler
- 16 row Mocal oil cooler with thermostatic sandwich plate
- Full 3” stainless exhaust system
- Oil pressure, temperature and boost gauges
- Remap
The end result was [finally a few pictures]:
(http://imagizer.imageshack.us/v2/640x480q90/824/x8oo.jpg) (https://imageshack.com/i/mwx8ooj)
(http://imagizer.imageshack.us/v2/640x480q90/834/limavady2013041400211.jpg) (https://imageshack.com/i/n6limavady2013041400211j)
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20130414-00202.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20130414-00202.jpg.html)
After getting it mapped with a K03 – it made 175bhp using 17-18 psi of boost – he then took it down to 170bhp with 6 less ftlb. of torque and said its at its limit in fuelling and this made it slllllightly safer…. He is an absolute genius and pulled a ridiculous torque figure out of the map which I’m not going to post as I reckon it will get slammed. And since I didn’t take a video or picture of the mapping session or get a printout of the figures, I cannot backup my claim other than say it’s my word.
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I ran the K03 setup for most of 2013 until it was time to put it in the garage for the winter months.
It was fun, but the engine started to breath really heavily and filled a catch tank in no time. So I figured, now was a good a time as any to start my 1341 rebuild.
I was initially planning on fitting a K03 hybrid turbo as advised by my mapper, but wanted to try a K04 …. It’s the K04-023 and not the K04-015 [with the k03 housing etc.] so I have no idea what the lag will be like.
Comparison of K03 to K04
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140308-00635.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140308-00635.jpg.html)
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And so the rebuild began:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20131222-00526.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20131222-00526.jpg.html)
With the engine out, the bay in need of some TLC – watch this space ------------
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140308-00619.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140308-00619.jpg.html)
The lil’ Polo in a sad state
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140308-00615.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140308-00615.jpg.html)
Terrible picture, but a few parts from the mountain of new parts
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140220-00590.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140220-00590.jpg.html)
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Fitted the new main end bearings/thrust washers with my nice freshly balanced/polished crankshaft [Thanks to Yousaf! Thanks bro! And fitted the oil pump along with crank housings with new seals and gaskets :)
For those who don't know, the engineering company I got to do the boring of the block and the balancing of the crank, removed the oil sprocket of the crankshaft which is not meant to come off [and I suspect they broke it]. I'm not the first person this happened to as another guy on this forum ran into similar problems with a different engineering company. His story was a bit more painful as small claims court was involved.
To cut a long story short, the company in question were happy to help me out, and replaced the crankshaft free of charge by buying one off Yousaf and then balanced and polished it all again for free :) - Took 2 months in total from the time I left my block/crankshaft down with them to the point where I got it all back [in one piece].
Out with the old:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140308-00627.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140308-00627.jpg.html)
And in with the new:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140302-00603.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140302-00603.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140302-00601.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140302-00601.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140302-00600.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140302-00600.jpg.html)
When I was fitting the oil pump, the Haynes manual just says 20nm which I now realise were for the 2 main bolts of the oil pump. The 2 small bolts used to bolt the mounting bracket to the block are not to be tightened to 20nm as I found out the hard way. There was no separate torque setting for these so tried to tighten them to 20nm, even when I thought to myself, that's a bit much since they're tiny.
Well I snapped it in the block and sat for half an hour with a screwdriver and a hammer trying to turn the bit to remove it. Did so successfully and then tightened a new bolt to 10nm of torque. Ironic that I used the torque wrench to avoid over tightening and that happened haha.
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I also fitted the pistons straight after the crank went in - what a nightmare - the ring compressor I had was pretty shit if I'm honest but it was borrowed so I can't complain too much. Was so scared of damaging the piston rings, this literally took me about an hour to do the 4...maybe more.
Then threw on the sump with new gasket and sealant.
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140308-00630.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140308-00630.jpg.html)
This is about all I could do at this point, so set about painting various bits of the engine including the block:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140308-00629.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140308-00629.jpg.html)
Before I took my engine out, it had developed a really horrible misfire on cold start-up which went away after 30 seconds. I figured it might have something to do with the auxiliary air valve not opening properly on cold start up [probably not the cause but worth eliminating] - so I put it in a de-gunking solution and cleaned it out properly, then sprayed it along with the water pipe which was a little ugly looking. Fitted a new water pipe gasket put them on to make it look like I was making more progress while I wait on other parts.
Old manky AAV
(http://i1149.photobucket.com/albums/o589/AdzCM/AAV.jpg) (http://s1149.photobucket.com/user/AdzCM/media/AAV.jpg.html)
Old rough looking water pipe
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140227-00598.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140227-00598.jpg.html)
Freshly cleaned and painted:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140308-00631.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140308-00631.jpg.html)
You can also see in the above pics that I fitted the lightened crankshaft along with new stretch bolts and Loctite - thanks to Peteg40 for supplying me with oil pump, con rod nuts, main crank cap bolts, timing belt crank sprocket and flywheel bolts. Cheers mate.
Better pic of the flywheel:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140308-00632.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140308-00632.jpg.html)
I wish I weighed it before and after, but didn't have a set of scales that could weight that much. Theres quite a lot taken off both sides. The recesses on the back which allow for a socket extension to fit when taking off the sump with the flywheel still on, are completely gone.
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Few other things I painted:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140308-00625.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140308-00625.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140308-00626.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140308-00626.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140310-00644.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140310-00644.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140310-00645.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140310-00645.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140312-00646.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140312-00646.jpg.html)
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The standard interior of the G40 is lovely looking, but only when in really good condition. My front seats were pretty good but my back seat was faded and looked almost pink.
So my mum [being an upholsterer] wrapped my seats in black leather [not real leather but no idea what the material is actually called...its like fake leather if that makes sense]
Here is a really bad picture of the back seats, but they look awesome in person. So chuffed with them.
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140308-00621.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140308-00621.jpg.html)
I will put up better pics when the car is finished. Front seats are done too but forgot to take a picture of them.
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That is pretty much me up to date.
I am getting my mate to fit the quaife differential along with whatever new bearings/seals its requires.
Getting a helix paddle clutch and beautiful deep dish steelies from Yousaf. They will be sprayed grey :)
And I'm waiting on my new BVH to be finished. Should be around mid April time.
It shouldn't be long then before I will have it finished and ready for its run in!
Will keep you posted.
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Are you still running a standard MAP sensor? If so, that'll be what's holding you back if you're aiming for well over 15psi.
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Cracking work, good bit of motivation to hurry my engine rebuild along
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Are you still running a standard MAP sensor? If so, that'll be what's holding you back if you're aiming for well over 15psi.
Yeah, I know about the MAP sensor cheers. My mapper advised me to wait until I fitted the forged pistons and rebuilt the engine before upping the boost/fuel, which was good advice as I don't think the engine was anywhere near healthy enough to hack it.
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Cracking work, good bit of motivation to hurry my engine rebuild along
Thanks man. You done much? Waiting on parts to arrive is the worst. I've done all I can do and it took no time at all. Need the head to finish it :(
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Who's 'your mapper'?
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Dave Wishart from Torquetronix here in Northern Ireland.
http://www.torquetronix.co.uk/about.aspx
The guy is a genius :)
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Are you still running a standard MAP sensor? If so, that'll be what's holding you back if you're aiming for well over 15psi.
Yeah, I know about the MAP sensor cheers. My mapper advised me to wait until I fitted the forged pistons and rebuilt the engine before upping the boost/fuel, which was good advice as I don't think the engine was anywhere near healthy enough to hack it.
Fair enough. 15psi on a healthy bottom end is usually enough for 175bhp in my experience, so may well be that your old motor was a bit tired.
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Are you still running a standard MAP sensor? If so, that'll be what's holding you back if you're aiming for well over 15psi.
Yeah, I know about the MAP sensor cheers. My mapper advised me to wait until I fitted the forged pistons and rebuilt the engine before upping the boost/fuel, which was good advice as I don't think the engine was anywhere near healthy enough to hack it.
Fair enough. 15psi on a healthy bottom end is usually enough for 175bhp in my experience, so may well be that your old motor was a bit tired.
Yeah, I reckon it was. It was breathing really heavily and had more blow-by than I would have liked. Should be interesting to see how it goes with a 1341 :)
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With nothing else to do 'engine wise' I thought id go ahead and sort out the K04.
It had a few problems that needed to be sorted in order for it to fit and work.
First off, its the K04-023 from an Audi TT/S3 and has a hold in the exhaust housing for an exhaust gas temperature sensor [EGT] so I had to get this blocked up. I had thought about maybe even fitting an EGT sensor but figured it would be easier/cheaper to just block it up.
That was until after research I found the hole to require an M11 x 1mm pitch blanking bolt which were impossible to find.
So I bought an M12 x 1.25 brass blanking bolt/washer and an M12 x 1.25 top and bottom tap.
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140316-00652.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140316-00652.jpg.html)
I thought the tap might completely eat the existing threads and leave a smooth hole, but it didn't and worked a treat. The brass blanking bolt tightened right in :)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140316-00651.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140316-00651.jpg.html)
Then the forge actuator came in the post:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140320-00659.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140320-00659.jpg.html)
Fitted it to the K04 and the housing was just not going to fit with the radiator in its way so had to sort this.
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140320-00661.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140320-00661.jpg.html)
I thought about just switching the plate [that holds the actuator] the other way round, but it just wouldn't work because of the shape of the plate. So thought about using the standard actuators plate.
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140320-00664.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140320-00664.jpg.html)
Its only after I realised I could have just ground the other side of the plate where the actuator is crimped round the centre hole. Butchering it seemed to work just as well:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140320-00665.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140320-00665.jpg.html)
This allowed me to bolt the actuator to the other side of the plate:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140320-00669.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140320-00669.jpg.html)
Then allowed me to rotate the turbo housing to a much better angle for it all to fit:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140321-00678.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140321-00678.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140321-00679.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140321-00679.jpg.html)
Simple enough fix, but well worth it. Would be a massive pain if I couldn't get the housing rotated down more.
Does anyone else think there's not a lot of thread left on the actuator rod for pre-load? Where it sits now, the waste gate is closed tight, but just. If I had a red 17.5 - 20psi spring fitted, how much more thread [if any] would I need to put approximately 23psi on it? Might have to space the actuator away from the mounting bracket a bit...
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Absolutely loving this!! Has anyone fitted a k04 before?
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any ideas what the characteristics and driveability of the 04 would be like? it looks alot bigger than an ko3
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Absolutely loving this!! Has anyone fitted a k04 before?
Cheers buddy. I have no idea if anyone has fitted a K04-023 but I think a few have fitted a K04-015. A guy off here dan1300r has the K04-015 and it sounds like a really good setup. I might be the first to let you all know whether going K04 is a good idea or not haha.
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What do the last 3 numbers refer to? (-023 and -015)
Ta
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015 means the exhaust housing is from a K03 I believe. The 023 has a bigger exhaust housing and has a hole for an EGT sensor. Your trusty friend google could probably tell you more ;)
Adrian
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The K03 or K04 part just tells you which family the turbocharger is from, the numbers which follow indicate which variant it is (i.e. what size turbine and compressor wheels and what size and type of housings etc.)
Turbine and compressor housings and wheels can differ significantly even on turbos from the same family.
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Still waiting on the BVH :( so still doing anything and everything I can to keep me busy.
Got the gearbox back with Quaife diff fitted. Took ages with some heavy duty cleaner and then a wire brush drill attachment to prepare it for paint:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140411-00724.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140411-00724.jpg.html)
Then painted it:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140411-00726.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140411-00726.jpg.html)
Then painted the engine mount bracket and 5th gear case and finished it off:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140427-00758.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140427-00758.jpg.html)
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Loved the wheels I had on the car last year but always wanted a set of banded steels so got some :)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140324-00687.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140324-00687.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140324-00686.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140324-00686.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140324-00684.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140324-00684.jpg.html)
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Painted them Ford Nimbus Grey because its awesome against capri green IMO:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140427-00765.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140427-00765.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140427-00764.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140427-00764.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140427-00761.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140427-00761.jpg.html)
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Took off all the old oil saturated, crusty loom tape and redid the whole loom with new stuff:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140427-00771.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140427-00771.jpg.html)
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Refitted the front mount after doing a little bit of cutting/grinding/painting to make it all fit. Nothing serious:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140421-00738.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140421-00738.jpg.html)
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Thinking about getting a full respray at some point so I just did a rough job of spraying the bay. Might aswell wen the engine was out:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140330-00710.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140330-00710.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140427-00768.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140427-00768.jpg.html)
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I had fitted this to run with the K03 but didn't have a build thread back then. The location seems to be good enough as oil temperature was never a problem. Always sat around 60-80 if I can remember and when it got quite hot from spirited driving, it cooled quite quickly.
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140427-00774.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140427-00774.jpg.html)
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And here is where I stand with the engine..... Once I get the BVH it should be plain sailing. Nearly all parts have been purchased and are on their way, or I already have them.
Fitted the standard twin-v crank pulley to aid in fitting the timing belt as with the larger GT/3F pulley, the timing mark had to be bent out of the way. Once I've timed it up, I just have to replace the pulleys and bend the timing mark out of the way again.
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140417-00730.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140417-00730.jpg.html)
Next update will be when I get the BVH which will hopefully be within the next couple of weeks.
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Getting bored of waiting on the BVH, so did a few things to keep myself sane...
Sent my helix paddle clutch off to helix for a re-pad/re-hub as it was pretty worn and then fitted it so I could bolt the gearbox to the engine along with the starter motor
Fitted the Knock sensor too and made sure it was torqued correctly.
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140505-00788.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140505-00788.jpg.html)
Then I finally got it out of the house, and into the car [in the dusty garage, hence the cling-film] - got the alternator on and wired up and connected up the sandwich plate and oil temperature sensor/wiring. Also connected the driveshafts up again and the coil pack and alternator earth straps. Then fiddled about with the gear linkage/engine mounts to get it to select all the gears - still not 100% - pain in the ass to be honest! then fitted a new clutch cable and the helix paddle clutch is definitely quite stiff.
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140508-00791.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140508-00791.jpg.html)
Then I fitted my new catch tank. Got one that would fit into the charcoal canister hole - it fits well enough for me but I'm a little worried about the filter. How bad will the fumes coming out of the filter? Don't want it to mess up the engine bay...
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140519-00835.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140519-00835.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140519-00837.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140519-00837.jpg.html)
Then wired up my new wideband lambda gauge and made a nice install so that its pointing up at an angle for me to see easily.
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140513-00798.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140513-00798.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140514-00815.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140514-00815.jpg.html)
All the gauges ill need now.
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140514-00814.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140514-00814.jpg.html)
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Also since I got a full black leather interior, the old faded door cards didn't quite fit in.
So got some fabric spray that definitely smartened up the interior of the car. The entire interior is black now :)
Before
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140515-00821.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140515-00821.jpg.html)
After
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140515-00822.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140515-00822.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140518-00833.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140518-00833.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140517-00826.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140517-00826.jpg.html)
Before
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140515-00819.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140515-00819.jpg.html)
After
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140515-00824.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140515-00824.jpg.html)
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Distributor with new o rings, leads, cap and rotor arm + a bit of paint.
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140520-00841.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140520-00841.jpg.html)
And a wee pic of the car in need of a wash....
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140517-00830.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140517-00830.jpg.html)
Really close to getting the BVH now - must be a really busy time of year because I've been waiting patiently for ages! - Once I get it, you better believe it will be a few hours and I'll have it started!
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Waiting is a real ball ache! Especially for car parts! But the car is coming together very nicely!
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Waiting is a real ball ache! Especially for car parts! But the car is coming together very nicely!
Tell me about it mate. I've been waiting since early march. What makes it worse is, all I need is the head and I'm good to go. Could have had the car on the road ages ago. Was such nice weather at Easter too :(
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I remember what felt like and eternity waiting for the group buy on my ppp mani and system lol, was just waiting for that and I could box her up
You got any more pics of those seats?
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I remember what felt like and eternity waiting for the group buy on my ppp mani and system lol, was just waiting for that and I could box her up
You got any more pics of those seats?
(http://i1149.photobucket.com/albums/o589/AdzCM/a83a3bd0-2a8d-4481-8054-f79ff9794afc.jpg) (http://s1149.photobucket.com/user/AdzCM/media/a83a3bd0-2a8d-4481-8054-f79ff9794afc.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/69891bd8-eb8a-4e80-a5c4-77efe2bcb496.jpg) (http://s1149.photobucket.com/user/AdzCM/media/69891bd8-eb8a-4e80-a5c4-77efe2bcb496.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/07c3d1a5-2bb1-4b91-a87f-89efdd3a5119.jpg) (http://s1149.photobucket.com/user/AdzCM/media/07c3d1a5-2bb1-4b91-a87f-89efdd3a5119.jpg.html)
They need cleaned and sat in a bit. I'm happy with them anyway :)
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Sweet!!! :D
like the gearstick too mate! is it a vw motorsport one?
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Sweet!!! :D
like the gearstick too mate! is it a vw motorsport one?
I have no idea mate haha, it was there when I bought the car. Assumed it was the standard gearstick. Is it not?
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Don't think so, mine is a hard plastic one like you get on poverty spec golfs
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leather gearknobs were an optional extra
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leather gearknobs were an optional extra
Don't suppose you have one lol, looks swish
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BVH Update..........................The BVH is ready ;D ;D ;D
Just have to wait on it to get posted along with my ported gt inlet manifold.
Might get this on the road before xmas...
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FINALLY!!!!!!!
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140619-00937.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140619-00937.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140619-00938.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140619-00938.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140619-00943.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140619-00943.jpg.html)
Then test fitted the K04, and it goes in so easily :) - was worried that it might be a struggle to get it to fit, but literally 10 seconds and it slots into place!
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140620-00949.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140620-00949.jpg.html)
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Couple of pics I forgot to add. Shows how clean the engine is...also bit of porting done to the gt inlet manifold.....
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140621-00955.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140621-00955.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140623-00963.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140623-00963.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140619-00934-1.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140619-00934-1.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20140619-00935-1.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20140619-00935-1.jpg.html)
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So, got it all finished last week, started it up, ran it up to temperature and it all seems fine :) ... still have a standard rocker cover bolt on its way, so will replace the temporary middle on as soon as it comes....
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140627-00980.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140627-00980.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140702-00985.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140702-00985.jpg.html)
Pretty happy with the way I piped the turbo to the intercooler...
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140626-00974.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140626-00974.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140626-00973.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140626-00973.jpg.html)
Then got the exhaust and downpipe modified to fit with 2 lambda bosses welded in for the standard and wideband lambda sensor....it is nicely tucked into the tunnel and doesn't hang low anywhere...bad pic, but you get the idea...
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140702-00993.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140702-00993.jpg.html)
Then a few pics of the car at the height I intend to keep it. Much better height for the roads around where I live. Still handles great, wheels don't foul on the arches and it still looks good...Liscence plates are just to get me through m.o.t. but will be fitting the pressed plates again because I think they're awesome.
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140702-00984.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140702-00984.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140702-00988.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140702-00988.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140704-01001.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140704-01001.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140702-00992.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140702-00992.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140702-00987.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140702-00987.jpg.html)
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Have driven the car about 40 miles so far. All seems ok. Bit worried that I'm not running it in correctly. I'm not going above 2000rpm and I've read countless times that I should at least do a few bursts to about 3500rpm to get the piston rings to seat properly.
What do you lot think?
New accelerator cable came sourced by VW Heritage. For those of you that think they are hard to get, you can still get them from them anyway...
Had to replace it, as the plastic ribbed bit on my old one had worn, and the little metal clip occasionally slipped. Conveniently at the times when I really could have done with it not slipping [overtaking etc.]......
Old:
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140702-00997.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140702-00997.jpg.html)
New:
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20140702-00996.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20140702-00996.jpg.html)
Its a perfect fit :)
I need to set the ignition timing and get the idle and fuelling set properly to pass emissions. M.o.t. is the 18th, but I'm ringing up every morning to try and get a cancellation because driving this car again has been long overdue! Will keep you posted...
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So so nice this man some right work has gone into it! Needs to come to tatton and/or leeds!
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Thanks man, only just noticed this comment haha. Would love to got to a few shows but its finding the time to get over to the mainland.
UPDATE:
Failed the MOT [18th July] due to battery failing so I couldn't complete the test. On the way home it kept popping out of 5th gear so I assumed an adjustment of the gear linkage was all that was needed. Got home and realised it wouldn't come out of fifth gear. After loads of fiddling about, I got it free and tried to set the linkage but couldn't manage to get 5th gear no matter what.
Took it out the next day and there were terrible grinding/chirping noises coming from the gearbox. So took it to the guy who fitted my LSD and left it with him. Came back and he told me that 5th gear was done because he forgot to put gearbox oil in it.......LOL good times!
Searched for about 2 months for a 5th gear getting much appreciated advice from guys on here. Eventually found one and took it to him. Turned round and said it was the 5th gear synchroniser ring and synchronising hub/locking collar. What a Moron...... Went onto clubpolo and found a guy who had what I needed, who posted it asap and It only cost me like £25.....
Finally got the gearbox sorted [with gearbox oil this time] free of charge as expected! Booked MOT and had to wait another 3 weeks for that [23rd October] .... FINALLY it passed!
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Got bored of the wheel colour very quickly. Had them that colour with the last wheels and something just isn't right this time. The black centres don't look right.
So sprayed them a different colour. Will post pics later...
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Great thread this, nice work.
Looks awesome on the above pictures, what are the specs on the wheels are they staggered?
Crazy situation with gearbox..who was that guy
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Its a little dark so the pics aren't the best, but you get the idea :)
Got my inspiration from Etches G40. They look awesome! Black wheels on a white car is the only way to go IMO. Thought they would make mine look a little 'meaner' which I think they do!
Will probably get better pics up later at some stage!
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20141025-01092.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20141025-01092.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20141025-01091.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20141025-01091.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20141027-01099.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20141027-01099.jpg.html)
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Great thread this, nice work.
Looks awesome on the above pictures, what are the specs on the wheels are they staggered?
Crazy situation with gearbox..who was that guy
Thanks mate :)
The wheels are 8J and I had them spaced at the back, but they stuck out far too much and I wanted to lower the car a bit more, so did away with the spacers. If I could do it again, I would have got something a little narrower. 8J but measure over 10" across the wheel and they are a bit wide. I may change them if I get too much wheel spin once mapped, since the tyres are stretched a bit. Probably can't have the look I want if I'm to put down the power I want.
Oh and the guy was a friend of my dad's. Usually really good with what he does. Must have had a bad day!
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I've done just over 800miles now relatively trouble free, apart from the alternator is acting up. The battery light stays on for a bit about a minute after start-up. There is a little bit of alternator belt squeal at low revs and on down changes. The lights brighten up as I rev and it idles like crap sometimes and cuts out occasionally when pulling up to lights/junctions etc.
Must be getting worse as my a/f gauge used to read solid 14's at idle and while driving off boost. But with lights on, its drops to a solid 13. Turn the lights off, and it goes back up to 14.
I've tightened the belt as much as I can. Going to see if that was the problem, otherwise ill need a new alternator.
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Did a bit of research and was put off using the main vacuum source from the inlet manifold to power the actuator.
The K03 as you know has a hose barb fitted to the compressor housing used for the actuator source.
Rather than tap the compressor housing, I fitted one of these:
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG-20141029-01101.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG-20141029-01101.jpg.html)
Came with a handy little too to cut a hole in the silicon pipe connected to the turbo and its good n air-tight.
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20141029-01102.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20141029-01102.jpg.html)
(http://i1149.photobucket.com/albums/o589/AdzCM/Limavady-20141029-01103.jpg) (http://s1149.photobucket.com/user/AdzCM/media/Limavady-20141029-01103.jpg.html)
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Also, red actuator spring came in the post, uprated map sensor is on its way and REMAP is booked for next week :)
Should be well into the 200bhp's
I'll be recording the whole process via GoPro ;)
Cannot wait!
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Coming together very nicely
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About time I updated this a bit...
Spec was:
- K04
- BVH
- 250kPa MAP sensor
- 77mm Forged Wossners
- Ported GT inlet manifold
- 51mm TB
- EV6 315cc Injectors etc.
First off, the mapping was a nightmare. The mapper didn't have an EPROM emulator to start with but the thing is, he didn't need one the last time he mapped the standard engine to 170bhp with 17.5psi on a K03. He couldn't get it to fuel right at all. There just wasn't enough fuel no matter what he did. He said I should just get an adjustable FPR and tune it that way.
So I fitted one and we put it on the hub dyno. Ran the K04 it at 16psi and adjusted the FPR until my a/f gauge showed it having loads of fuel. It made 201bhp and 174lbft in 3rd gear. Couldn't get it to dyno in 4th whether it was his dyno or my Quaife diff??
It was quick, but the dyno graph was crap to be honest. Had flat spots and had nothing after 6000rpm.
The peak boost of the K04 was 4000rpm. So a power band of 4000-6000rpm wasn't that great.
Drove it like that for a while. One problem was, in order to have enough fuel throughout the rev range, it was seriously rich at idle.
When I say it was quick, it was only as quick as it was when I had the standard engine at 170bhp. It was actually much quicker at 170bhp because it would pull past 140mph in no time, whereas this time it struggled to pull 135mph [which took ages compared to 170bhp]. So ££££'s put into it since 170bhp and its slower. Brilliant!
Posted the graph on here, and gathered from everyone who commented, that in order to get more power from the K04, I would need to increase the rev range. To do that safely, I would be better fitting uprated con rods. Wasn't in the mood to start taking a 1500k mile old engine apart to fit con rods. Plus, If I did get more power, I ran the massive risk of wrecking the gearbox. And how much power is too much power. A bad running 201bhp was hard enough to control with a Quaife diff. Had to learn how to drive the Polo all over again. The diff pulls you all over the road if the road surface is bad.
So with all this in mind, I went back to the K03 setup and refitted the standard FPR. Ran 21psi and got a chip from Andy. IT STILL WOULD NOT RUN! Completely lost as to why it wouldn't work.
Lot of back and forth messages with Andy to try to sort it. Cannot thank him enough for that. Top man.
Long story short, in the end he asked me for the part number of the 315cc injectors. He got back to me and said that the EV6 style injectors [the ones I had fitted] have caused problems for him before. They have a wide spray pattern compared to the EV1 style injectors, which have a narrow spray. He reckons what could have been happening was, the EV6 injectors were spraying onto the walls of the inlet manifold, and gushing in rather than spraying into the cylinders in a fine mist [correct me if I'm wrong Andy].
He said change to a set of 315cc orange top EV1 style injectors and sent me the part number. So I did, and the car ran perfectly!
This I a lot of writing and its not even half of the problems. I tried to shorten it. Was with my mapper on 3 separate occasions for example. I've been trying to sort this car for about 6 months. Finally, things are looking up.
I am now at the stage where I can hopefully get it mapped.
Adrian
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When I fitted the K03, I made sure to move the air filter. Before, it was up round where the standard air box sat. So it was just sucking in hot air and whats worse, it was in line with the catch tank filter. So most likely sucking in the fumes from that too.
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG_0633.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG_0633.jpg.html)
Also cut out the restricting parts of the grill. Has to be better positioned here than where it was before. Sure, its closer to the turbo, but when your'e driving down the road, it will be sucking in loads of cool, clean air.
(http://i1149.photobucket.com/albums/o589/AdzCM/IMG_0597.jpg) (http://s1149.photobucket.com/user/AdzCM/media/IMG_0597.jpg.html)
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Good work on getting to the source of it. I was stumped for weeks on a faulty earth in the ecu relay. Massive G smiles lately though on the weekend sunshine drives though
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Good work on getting to the source of it. I was stumped for weeks on a faulty earth in the ecu relay. Massive G smiles lately though on the weekend sunshine drives though
All on Andy that one. I would never have suspected injector spray pattern. Far as I was concerned, they were EV6 315cc injectors which are perfect for a G40. Says dubforcetuning. Rubbish. I can tell you they don't work in a g40 manifold. Standard EV1 315s worked perfectly! EV6 do not.
I looked at your thread before I started posting in mine the other day to see how you were getting on. Still no update so good to hear you're on the road again. It's so nice to have a brand new tuned engine. No leaks or paranoia etc :)
Best of luck bud
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Picking wheels up tomorrow, suspension is in the post and not far off a reshell. Updates will follow.
Yeah pulls well, thinking about a custom map as well. Just looking for a suitable spot to do it.
You will have to catch the boat over and have a few beers with us Yorkshire lads in Sheffield at some point