Club G40 Forum

Technical => Engine and Transmission => Topic started by: xrrich on January 12, 2012, 09:15:46 pm

Title: Project Starts - Turbo
Post by: xrrich on January 12, 2012, 09:15:46 pm

Hi, :)
So ive owned my G for 2 years now and have been fortunate enough to get myself a daily, so i can do some proper work to the G.

I was looking at starting the project but really just for a bit of advice before i start.

Everything i know is from what ive done on the car and previous cars, learning as i go.
I will be looking at fitting a fast road cam but not really tackled anything inside of the engine as of yet. So will take my time and get advice along the way.

I would love to take the engine apart and rebuild it, but would like to know how to assess for wear, things to change etc. If it doesn't need replacing why replace it.. porting and polishing, bigger pistons etc

Just to get some ideas flowing for what i shall do.

For the cam, i want the engine to be as healthy as possible so want to know what to change with it, Cam oil seal, tappets, cambelt and water pump?

I know alot of you have a deep knowledge about these cars and i would like to delve deeper and learn moree! :D

If anyone can take some time to give me some guidance and help, it would be much appreciated, i am also searching constantly on the web finding out interesting things

Many thanks
Rich




Just a few pics to show you how my car has been coming on over the past 2 years, i have replaced alot of things, and enjoyed every min of it even when it leaves me on the motorway stranded

(http://i32.photobucket.com/albums/d30/laluk_22/1487646-1CHANGGEDD.jpg)

Gaz Coilovers :P
(http://i32.photobucket.com/albums/d30/laluk_22/GAZcoilovers.jpg)

Leaky core plug :o :(
(http://i32.photobucket.com/albums/d30/laluk_22/photo9.jpg)
(http://i32.photobucket.com/albums/d30/laluk_22/photo10.jpg)

Charger Rebuild
(http://i32.photobucket.com/albums/d30/laluk_22/IMG00336-20101118-1229.jpg)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG00382-20101202-2132.jpg)

Toothies :)
(http://i32.photobucket.com/albums/d30/laluk_22/photo11-1.jpg)

Manifold
(http://i32.photobucket.com/albums/d30/laluk_22/264620_2208888859348_1161243485_32677780_3844621_n.jpg)

Managed to win The Meguairs 10th aniversary competition, Had a really good day and got an advert shoot.:D
http://www.facebook.com/media/set/?set=a.243644345658402.58897.137752586247579&type=1
http://www.facebook.com/media/set/?set=a.252645534758283.60438.137752586247579&type=1
http://www.facebook.com/media/set/?set=a.257816537574516.61439.137752586247579&type=1

(http://i32.photobucket.com/albums/d30/laluk_22/G402.jpg)
(http://i32.photobucket.com/albums/d30/laluk_22/322727_252449164777920_137752586247579_820799_2178942_o.jpg)

SantaPod
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_1239.jpg)

Edition38
(http://i32.photobucket.com/albums/d30/laluk_22/298357_2376985141650_1161243485_32888308_584844036_n.jpg)

Polo Show RR

(http://i32.photobucket.com/albums/d30/laluk_22/g40rollingroad.jpg)
(http://i32.photobucket.com/albums/d30/laluk_22/1534bhp.jpg)

Subframe ;)
(http://i32.photobucket.com/albums/d30/laluk_22/subframe.jpg)

As it stands next to the daily :)

(http://i32.photobucket.com/albums/d30/laluk_22/dailyyoaw-1.jpg)

Thanks

Title: Re: Project Starts
Post by: SuperMario on January 12, 2012, 09:42:27 pm

If you were to change the cam, id advise todo
the tappets with it. new cam and new tappets can wear together! and a cam seal is deffo a good shout!

As for the forged pistons, if your going that far into the engine i think you might aswell change the bigend bearings whilst your there! and the oil pump! £80 from vw iirc?  the last thing you'll want is to be taking you sump off again! 

unless your going to bore the engine out, forged pistons seem a waste of money! mabey just get some over bore piston rings from VW and hone out the bore?

after that, youll have yourself a strong engine!  taking it all on not knowing what your looking at tho! thats a bit dodgy if you ask me! good luck!

Title: Re: Project Starts
Post by: xrrich on January 12, 2012, 09:47:24 pm

Thanks, Yeah, lots of research is in order...i will be doing about 6 weeks of engine build at college as part of my apprentership soon so that will help me out, tbh i dont think i will go into forged pistons etc but we shall see.

Thanks for comment
Rich

Title: Re: Project Starts
Post by: SuperMario on January 12, 2012, 10:11:26 pm

yea that apprentaship will deffo help!

nice polo btw! always wanted a grey G when i was looking for one!

Title: Re: Project Starts
Post by: PeteG40 on January 13, 2012, 09:22:42 am

bottom end - gaskets, big ends, mains.

BTW oil pumps are about £175 at vw!!!

Title: Re: Project Starts
Post by: pettsy on January 13, 2012, 09:21:00 pm

Quote from: PeteG40 on January 13, 2012, 09:22:42 am

BTW oil pumps are about £175 at vw!!!

i got one from vw for £120 last year

Title: Re: Project Starts
Post by: Raw on January 13, 2012, 09:21:33 pm

If you're taking the head off and tappets out, you may as well reseat the valves and replace the valve stem oil seals.

And if you're taking the valves out you may as well clean up the ports & match the inlet manifold.

Maybe even check the flame face for straightness. A local job shop can do this if you're not sure, and could skim the head if necessary.

Andy

Title: Re: Project Starts
Post by: xrrich on January 14, 2012, 12:23:36 pm

Ok cool yeah was thinking just take the head off leaving the bottem end
Best place to buy valves vw or would it be worth putting bigger ones in?

Thanks
Rich

Title: Re: Project Starts
Post by: Raw on January 14, 2012, 02:00:27 pm

No need to put new valves in. You can just re seat the old ones with grinding paste - buy a kit including the "dibber" here for example http://www.amazon.co.uk/Holts-Valve-Grinding-engine-valves/dp/B004PZUW18

Title: Re: Project Starts
Post by: xrrich on January 14, 2012, 05:53:35 pm

Ahh yeah was watching a video on this yday so you can used the same valves, he attached a electric screwdriver to the underside of the valve lapping the valve that way looked abit vicious lol,

Title: Re: Project Starts
Post by: Raw on January 14, 2012, 07:52:15 pm

I think the manual way is safer! I'm sure I remember somebody telling me that it's important to change directions often (as you do with the manual "dibber" tool).

Title: Re: Project Starts
Post by: xrrich on January 14, 2012, 09:04:17 pm

Yeah looked a bit.... well didnt look right, how do you tell when they are seated correctly?

Title: Re: Project Starts
Post by: Raw on January 14, 2012, 10:19:01 pm

I'm not sure exactly.

You could try using some engineers blue (the kind that doesn't dry out) in the following way:

After cleaning the grinding paste off apply a thin smear to the valve seat and drop the valve back in, give the valve a little twist and withdraw, check there is a nice unbroken line of blue on the valve, look for any areas that are especial thin or broken. Work in reverse (by cleaning the valve seat and applying more blue to the contact area on the valve) to check the valve seat.

A word to the wise; when removing valves make sure the valves are clearly marked and get replaced back in the same ports (keep springs & collets matched also)

Title: Re: Project Starts - Going Turbo!
Post by: xrrich on March 13, 2014, 07:16:33 pm

So, this was started but to be honest I’m not really much of a build thread kinda guy,

I’m am now going turbo , and from the research I have been doing I have found other build threads useful so I  thought I would share with everyone how I found the process

Current Spec
Jabba Air filter with heat shield
PPP Exhaust twin silenced
PPP Manifold Old shape
65mm PSD toothed pulleys
R1 Spec Charger
Boost return modification
51mm Throttle body
GT inlet manifold
G60 injectors
Big valve head + flowed  - PSD
Schrick cam
QUIAFE LSD

Think that is it...


Basically I was fed of my charger scroll seals blowing ever couple of thousand miles if I drove it hard.

Before things kick off I sent my front Gaz coilovers for a service as one was leaking, our fairly new addition to the family as well 5 month old fox red Labrador Rio  :)

(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_08121_zps565ef3c5.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_08121_zps565ef3c5.jpg.html)

So here goes.... the turbo battle begins, I have gathered some parts of the last month or so here goes

AS she stands at the minute
(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_08141_zps350af94e.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_08141_zps350af94e.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_08151_zpsc27572d2.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_08151_zpsc27572d2.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_08161_zpscdcbc3a4.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_08161_zpscdcbc3a4.jpg.html)

Here are a few bits I have collected

Rothe Manifold
(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_08221_zpscfd824e5.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_08221_zpscfd824e5.jpg.html)

KO3 with forge actuator
(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_08391_zps65b74011.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_08391_zps65b74011.jpg.html)

Downpipe
(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_08361_zps141c7e20.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_08361_zps141c7e20.jpg.html)



PSD Cam

(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_08251_zps2579af96.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_08251_zps2579af96.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_08241_zps803aa136.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_08241_zps803aa136.jpg.html)
PVL Switch
 
(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_08371_zps0429d627.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_08371_zps0429d627.jpg.html)


I will hopefully make a start this weekend

Title: Re: Project Starts - Going Turbo
Post by: xrrich on March 16, 2014, 08:34:52 pm

So I did some work over the weekend,

Saturday I stripped from the car -  Charger, Intercooler, Radiator, Plastics, Bumper, Front beam, Sump, Subframe, passenger driveshaft, alternator, and block pulley.

She now looks like this :( .. looks so empty

(http://i32.photobucket.com/albums/d30/laluk_22/IMG_08641_zps3173c5c9.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_08641_zps3173c5c9.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_08661_zpsd81020a7.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_08661_zpsd81020a7.jpg.html)

I also fit new sump with welded oil drain for turbo

(http://i32.photobucket.com/albums/d30/laluk_22/IMG_08801_zpsd20dc2c0.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_08801_zpsd20dc2c0.jpg.html)

Tonight I have fit the new engine mount, pulleys belt and alternator back on, nothing too exciting, I also fitted a blanking plug for the old oil drain for the charger.

(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/5fa561fa-5ba6-41cf-9d2c-58f1b4d620b2_zpse0eb42ab.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/5fa561fa-5ba6-41cf-9d2c-58f1b4d620b2_zpse0eb42ab.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_10301_zps80bf4b34.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_10301_zps80bf4b34.jpg.html)


I couldn't resist so I “test fit” manifold and turbo and downpipe to make sure it all fitted ok etc

(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_10661_zps84459683.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_10661_zps84459683.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_10671_zps5be2d319.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_10671_zps5be2d319.jpg.html)

Title: Re: Project Starts - Going Turbo
Post by: z3i on March 16, 2014, 09:09:29 pm

Looks good man!! the sump looks really good! :)

Title: Re: Project Starts - Going Turbo
Post by: xrrich on March 17, 2014, 05:09:19 pm

Thanks man :)

Title: Re: Project Starts - Going Turbo
Post by: xrrich on March 17, 2014, 05:13:32 pm

Bit more work done today
Intercooler fitted - ordered boost hoses today

(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_09541_zpsbd841f90.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_09541_zpsbd841f90.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_09551_zps1f3d33bc.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_09551_zps1f3d33bc.jpg.html)

(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_11201_zpsdcebc46e.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_11201_zpsdcebc46e.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/IMG_11211_zps3400a074.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/IMG_11211_zps3400a074.jpg.html)

Title: Re: Project Starts - Going Turbo
Post by: xrrich on April 27, 2014, 08:17:18 pm

So yeah ..

Next up was the radiator, I bought this from eBay, it is really good
Welds arnt that pretty but is decent

(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/Pictures/504FDCDF-414B-4DAA-9AC0-1A1B975E3656_zpsbbxjjqio.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/Pictures/504FDCDF-414B-4DAA-9AC0-1A1B975E3656_zpsbbxjjqio.jpg.html)

I bought a cheeky fan

(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/Pictures/36C1417F-90E8-4656-8D56-CB0EABF6BB07_zpsccwxok5z.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/Pictures/36C1417F-90E8-4656-8D56-CB0EABF6BB07_zpsccwxok5z.jpg.html)

(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/Pictures/1827F1C8-7935-4C4C-937C-CDB4247719FD_zpsktodutza.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/Pictures/1827F1C8-7935-4C4C-937C-CDB4247719FD_zpsktodutza.jpg.html)

I cut out a small bit at the bottem so it sit flush against the core

(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/Pictures/36C1417F-90E8-4656-8D56-CB0EABF6BB07_zpsccwxok5z.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/Pictures/36C1417F-90E8-4656-8D56-CB0EABF6BB07_zpsccwxok5z.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/Pictures/EFCAD927-6D5D-4450-A220-7AB412D28326_zpsj74mdjgb.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/Pictures/EFCAD927-6D5D-4450-A220-7AB412D28326_zpsj74mdjgb.jpg.html)

All being good but then I came to for the fan switch and going out the hole is a different size aha
So I orderd an adapter from my loc hydralics place


(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/Pictures/2B874A29-98E4-409A-A004-6837F6719992_zpsx8khfqdl.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/Pictures/2B874A29-98E4-409A-A004-6837F6719992_zpsx8khfqdl.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/Pictures/810CAE74-0F4A-403B-9118-43782B2CC056_zpsfpc2dgf2.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/Pictures/810CAE74-0F4A-403B-9118-43782B2CC056_zpsfpc2dgf2.jpg.html)

I recieved this from the hydralics place

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/9FF06224-29F4-44BA-A8B6-102134F6AF34_zpsz3gufexp.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/9FF06224-29F4-44BA-A8B6-102134F6AF34_zpsz3gufexp.jpg.html)

So I modified it
(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/C700C0C6-5D6B-49E4-974E-DAC670601A71_zpsethzsfac.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/C700C0C6-5D6B-49E4-974E-DAC670601A71_zpsethzsfac.jpg.html)

Title: Re: Project Starts - Going Turbo
Post by: xrrich on April 27, 2014, 08:23:45 pm

As I snapped my old driveshaft at Santa pod last year I treated myself to an uprated one

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/B065511F-8EB7-42C9-A011-E43C1718B37E_zpsjowntiav.png) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/B065511F-8EB7-42C9-A011-E43C1718B37E_zpsjowntiav.png.html)

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/326AD9B7-4CBE-43D0-B907-F2CB2B4F59FC_zpsaaqx4srz.png) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/326AD9B7-4CBE-43D0-B907-F2CB2B4F59FC_zpsaaqx4srz.png.html)

Uprated :) I changed the cv boots for good measure

(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/Pictures/1E003172-7167-411B-9647-EC473D1F5A3B_zpspmqwftko.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/Pictures/1E003172-7167-411B-9647-EC473D1F5A3B_zpspmqwftko.jpg.html)

Title: Re: Project Starts - Going Turbo
Post by: xrrich on April 27, 2014, 08:27:25 pm

I fit the cam shaft PsD 268 with a new camshaft seal


(http://i32.photobucket.com/albums/d30/laluk_22/RICHPC/Pictures/2BB16544-A795-4CC0-B7A7-A4B5E9228EEB_zps8ke6w4wh.jpg) (http://s32.photobucket.com/user/laluk_22/media/RICHPC/Pictures/2BB16544-A795-4CC0-B7A7-A4B5E9228EEB_zps8ke6w4wh.jpg.html)




Next.. I had to remove this as when I turned it over by hand it was catching on the teeth of the alternator belt

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/CA56E018-E367-4502-AEFF-7845B468F45D_zpskt6sswa2.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/CA56E018-E367-4502-AEFF-7845B468F45D_zpskt6sswa2.jpg.html)

Title: Re: Project Starts - Going Turbo
Post by: xrrich on April 27, 2014, 08:38:06 pm

So I've missed out a few things as I started to get excited and not take photos

Pressure switch is plumbed into the inlet manifold
I wired the fan up
Plumbed the water hoses in for the turbo and sorted all the boost hoses out
So she is getting there

I changed the discs to drilled and grooved
Braided hoses and some new brake pads

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/FFD2282A-1140-4C3D-A49F-CC050B5A05CC_zpsrukgkeye.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/FFD2282A-1140-4C3D-A49F-CC050B5A05CC_zpsrukgkeye.jpg.html)

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/F04EB6EA-8E7D-41A0-AA10-04A9F417A7FD_zpsv55iccwd.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/F04EB6EA-8E7D-41A0-AA10-04A9F417A7FD_zpsv55iccwd.jpg.html)

Andy very kindly sorted me out with a cheap even though he is very busy.. Thanks Andy!
And Kieron has been advising me the whole journey .. Thanks bud!!

Here is is.. I finished yesterday, got the exhaust back on and last few things


(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/D450C4EE-E361-48AC-88DE-D5CE022030A0_zpstmfw1ltb.png) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/D450C4EE-E361-48AC-88DE-D5CE022030A0_zpstmfw1ltb.png.html)

Title: Re: Project Starts - Going Turbo - Done with some troubles :(
Post by: xrrich on April 27, 2014, 10:10:07 pm

So I managed to drive it for about 6 hours before I blew the head gasket

 (http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/6661E961-887D-4A7D-96B3-27E3620BDA6E_zps9levmt79.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/6661E961-887D-4A7D-96B3-27E3620BDA6E_zps9levmt79.jpg.html)

Aha I thought it was a melted piston so I was happy to strip it down And find te piston was ok..
Bit tbh I was looking forward to getting a new bottem end and forged internals aha

So I've been researching whether to go for 6n metal
Or a victor rienz standard
 
(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/521288A9-4E73-43F5-AC17-DFD45A5C5585_zpsknvqk7zo.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/521288A9-4E73-43F5-AC17-DFD45A5C5585_zpsknvqk7zo.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/9C979049-DBA7-47F5-AB60-4AC6F8654620_zpspdn8debk.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/9C979049-DBA7-47F5-AB60-4AC6F8654620_zpspdn8debk.jpg.html)

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/714E38CA-96CD-4FCF-B661-4D2C1DE22399_zpstcohjyeh.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/714E38CA-96CD-4FCF-B661-4D2C1DE22399_zpstcohjyeh.jpg.html)




Things I am going to change

I'm going to adjust the actuator because I think it's running a bit too much boost for the standard map sensor

I need to order an oil cooler before I start driving hard

Steering rack needs adjusting as there is a lot of play

Change my clutch as it's slipping now aha

Title: Re: Project Starts - Going Turbo - Done with some troubles :(
Post by: Etches on April 27, 2014, 10:15:40 pm

I'm using the 6n gasket at the min dude, dont think you should rush the oil cooler I had one on but when my pipes split took it off. Oil temps have been fine without it! What clutch you using dude? Looking good though, glad you've gone turbo :)

Title: Re: Project Starts - Going Turbo - Done with some troubles :(
Post by: xrrich on April 27, 2014, 10:29:58 pm

Yeah a few people have said use the 6n one

I've got a helix race ready to go in, but I'm going to get it re sintered before I put it on because it's second hand
Not sure  what clutch is in it ATM it's the one in since I bought it and instantly started slipping when I fitted the turbo

I am so glad I went turbo felt so different but fun to drive, I was surprised that there was hardly and lag!  aha although I think turbo might be slightly weeping, it smokes .. We smoked from cold but when warm it was fine

Going to get the head gasket and bolts ordered tomorrow and get it back on the road for the weekend hopefully

Title: Re: Project Starts - Going Turbo - Done with some troubles :(
Post by: RyanC on April 28, 2014, 04:50:43 pm

Nice work man, ha I just got one of those radiators looks like I'll have to get an adapter too :L

Title: Re: Project Starts - Going Turbo - Done with some troubles :(
Post by: xrrich on April 28, 2014, 05:25:45 pm

Quote from: RyanC on April 28, 2014, 04:50:43 pm

Nice work man, ha I just got one of those radiators looks like I'll have to get an adapter too :L

Thanks man.. Yeah I want to get a proper one made up as I am anal like that.. Get a lad at work to turn me one down out of alloy would be nice..

Other that that though the radiator is sound!

Anyway I went to GsF today and got a few goodies
Elring metal head gasket
Erring camshaft seal
Inlet manifold gasket
Some coolant
And some head bolts

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/D562A8FD-B8D5-41D5-97C4-A7FC18706E37_zpse7qhv8oj.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/D562A8FD-B8D5-41D5-97C4-A7FC18706E37_zpse7qhv8oj.jpg.html)

Getting my head skimmed on Wednesday after work so will be building it back up probably Friday :)

Title: Re: Project Starts - Going Turbo - Done with some troubles :(
Post by: xrrich on April 29, 2014, 05:51:14 pm

Posted my helix clutch off to get re padded today woop

Title: Re: Project Starts - Going Turbo - Done with some troubles :(
Post by: runforrestrun on April 29, 2014, 07:47:39 pm

How much is it setting you back to get it re faced?

Title: Re: Project Starts - Going Turbo - Done with some troubles :(
Post by: Etches on April 29, 2014, 07:49:43 pm

75 is what they quoted me on the phone

Title: Re: Project Starts - Going Turbo - Done with some troubles :(
Post by: xrrich on April 29, 2014, 09:06:22 pm

Quote from: runforrestrun on April 29, 2014, 07:47:39 pm

How much is it setting you back to get it re faced?

£56 plus VAT and Carriage

Title: Re: Project Starts - Going Turbo - Done with some troubles :(
Post by: xrrich on May 01, 2014, 10:19:03 pm

So I got my head skimmed today and new valve stem seals whilst it was off

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/45F5AB09-AB26-4102-96E5-9CBAAB2B0A3C_zpssh4dmko4.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/45F5AB09-AB26-4102-96E5-9CBAAB2B0A3C_zpssh4dmko4.jpg.html)

And she is back together

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/6BDD16EA-A93B-4F5B-89EF-E0B03BA0E063_zpsdluxzefu.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/6BDD16EA-A93B-4F5B-89EF-E0B03BA0E063_zpsdluxzefu.jpg.html)

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/ED5995F1-567E-49B4-8B62-4E4B7C6EBE2C_zpsgjky6vct.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/ED5995F1-567E-49B4-8B62-4E4B7C6EBE2C_zpsgjky6vct.jpg.html)

Apart from loosing the clip to hold the sensor in the black boost pipe in it all went ok.. Oh and the black temp sensor wiring snapped . They were so brittle
Been out for an hour or so drive and didn't blow it up aha

It does smoke from cold but as soon as it is warm it is fine????????
What could this be?
I am going to get my cam timing and ignition timing checked
Failing that could it be turbo?

Title: Re: Project Starts - Going Turbo - Done with some troubles :(
Post by: xrrich on May 11, 2014, 03:14:06 pm

So you probably saw from my thread I had a bit of fueling hesitation problem  after I snapped my rocker bolt, but this was  just a coincendance.

I snapped the bolt and removed the dizzy, rocker and cam bearing cap to remove the broken stud so I thought I had broken the dizzy or hall sender

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/5C655AFB-714D-43BA-A7A6-AD92BDDD8D54_zps9iyp7mcb.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/5C655AFB-714D-43BA-A7A6-AD92BDDD8D54_zps9iyp7mcb.jpg.html)

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/630E686A-9CC2-4810-BB31-F3B93E03655B_zpsxfvmwxpo.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/630E686A-9CC2-4810-BB31-F3B93E03655B_zpsxfvmwxpo.jpg.html)

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/9470DAB7-8214-4298-9861-1440E0D88CE8_zpsnlyl7bx0.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/9470DAB7-8214-4298-9861-1440E0D88CE8_zpsnlyl7bx0.jpg.html)


After....
I changed the dizzy I realised it wasn't that! So I thought of everything else it could be

I changed
 
Fuel pump relay
Fuel pump and filter, I was conviced it was this so after I took it our for a drive and someone crashed into the back of me at a roundabout which kinda just gave me the thought the  up and break it!


(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/917FA40D-DD0D-449B-A689-DDC3D3E8062C_zpsr3enn5kv.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/917FA40D-DD0D-449B-A689-DDC3D3E8062C_zpsr3enn5kv.jpg.html)

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/B3A96F99-A7F0-44A6-BD50-D617302BB804_zpsuongmjjb.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/B3A96F99-A7F0-44A6-BD50-D617302BB804_zpsuongmjjb.jpg.html)

I was so close to calling it a day but my mate came back from London and pushed me to get cracking

So we spend 5 hours on the car

I changed the ecu relay
Lamda sensor

I set ignition timing
Did compression test which was fine

Buttttt ...luckily my mate had left the ignition on and when I was tightening the last spark plug the ratchet swung round and touched the body, the fuel pump primed so I though there was a current coming from the engine to the body causing the fuel pump to prime.. I was thinking dodgy earth or a short somewhere, so we checked all the cables for damage but found bugger all

It wasn't until we realised it wasn't that there was a current going through. It was the vibration of the ratchet hitting the back panel where the ecu is.. This was shaking the ecu

I taped the ecu with the ignition on and it primed .. So I started the car and tapped the ecu and is hesitated and juddered

So I took the ecu apart and found that... Stupid me!! I hadn't pushed the chip in enough so it had worked loose!!

So it is sorted, very simple fix just stupid mistake from me, I was probably being carful putting it in not wanting to bend a pin or something




Anyway what is next...
Fix me shell?
Re shell?

Or sell? .... Nahhhh

In the mean time I will fit this baby so I can put the power down

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/4F44F918-05DB-47D2-9351-4811C822B4C7_zpscmevdwkw.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/4F44F918-05DB-47D2-9351-4811C822B4C7_zpscmevdwkw.jpg.html)

Title: Re: Project Starts - Turbo
Post by: z3i on May 11, 2014, 03:37:31 pm

Aha! glad you found the fault! accidental fault finding :P could have taken forever to find that!!!

Title: Re: Project Starts - Turbo
Post by: xrrich on June 16, 2014, 01:24:22 pm

So after driving it a bit i have found it is breathing heavily under load

I have done a compression test and cylinder 2 is down, so it is suspected piston rings.

new engine build coming shortly!!

Title: Re: Project Starts - Turbo
Post by: JoeH on June 16, 2014, 05:52:26 pm

What mileage is the engine at?

Title: Re: Project Starts - Turbo
Post by: xrrich on June 16, 2014, 06:13:53 pm

160,000
But when I first bought it the clocks were not working so who knows how long the previous owner drove it round like that for. I drove it got about 5000 with old clocks

So it could be 180,000

Title: Re: Project Starts - Turbo
Post by: Snave on June 20, 2014, 12:35:22 pm

good luck for the rebuild !

Title: Re: Project Starts - Turbo
Post by: xrrich on July 21, 2014, 03:12:21 pm

So its been a few weeks and i haven't posted because i've been busy with this (build thread coming shortly)
So my mate bought the car as he used to own a white one before it got written off
within a week of owining it i convinced him to buy a g40 lump and me and him managed to do it in two weeekends
started as a 1.3 carb -  2 week turnaround its a running g40

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/90EF94CE-8C73-4A99-A63C-1CD620587D19_zpszhoallqc.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/90EF94CE-8C73-4A99-A63C-1CD620587D19_zpszhoallqc.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/45FEF46D-851A-4B8F-A31C-DCFA7898279C_zpslhf5qljj.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/45FEF46D-851A-4B8F-A31C-DCFA7898279C_zpslhf5qljj.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/80B7F025-0E5C-4FF8-A493-4C4B7175080D_zpsg9alhlhg.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/80B7F025-0E5C-4FF8-A493-4C4B7175080D_zpsg9alhlhg.jpg.html)



So work has been slow on mine but .....
The engine has been built!!!!  ;D ;D ;D and i have covered 300 miles ish


All seems to be good so far

Here are a few photos because everyone loves photos

Engine out

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/DDE49E33-19D9-4621-8C46-018F369E439A_zpsbv5jnt4d.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/DDE49E33-19D9-4621-8C46-018F369E439A_zpsbv5jnt4d.jpg.html)


I stripped everything down and found out that there is a place very local that does superb work, so had the block bored with them.

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/69C90416-B018-43A7-BF23-852892BFCDC8_zpse8alp4ph.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/69C90416-B018-43A7-BF23-852892BFCDC8_zpse8alp4ph.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/F3A39BFF-2197-40F5-8150-90D714ABD481_zpslzchngtj.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/F3A39BFF-2197-40F5-8150-90D714ABD481_zpslzchngtj.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/C5DD41BE-0D14-42BE-A52A-8B5B72D1498A_zps7r4l7dtm.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/C5DD41BE-0D14-42BE-A52A-8B5B72D1498A_zps7r4l7dtm.jpg.html)

I got the block back after 2 days or so, and cleaned it the best i could to give it a paint.

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/B6A9C79B-42E3-4BE5-80D1-00A4201A198E_zpsssg9wmko.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/B6A9C79B-42E3-4BE5-80D1-00A4201A198E_zpsssg9wmko.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/3309735E-C124-4471-9E59-E7036A61AF92_zps2g3usahl.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/3309735E-C124-4471-9E59-E7036A61AF92_zps2g3usahl.jpg.html)

(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/FEEFFD51-6D8B-4311-BC20-0A00ED6B020C_zpseknbbfv3.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/FEEFFD51-6D8B-4311-BC20-0A00ED6B020C_zpseknbbfv3.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/2ACCFF85-C969-478F-AAB1-8C669264D6A5_zpsaopbkekf.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/2ACCFF85-C969-478F-AAB1-8C669264D6A5_zpsaopbkekf.jpg.html)

Then it was time to rebuild, i bought a
seal kit for the bottem end
accrilite pistons 1341
new circlips for the rods
metal head gasket and head bolts
waterpump
cambelt
oil filter
and every other gasket you can think of needed


(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/428FB40D-6288-41E1-B9FB-C6BC883773E7_zpsvl0i7ju1.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/428FB40D-6288-41E1-B9FB-C6BC883773E7_zpsvl0i7ju1.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/8660A210-E9E9-443D-A78F-178887B9A403_zpsfpc9m7iv.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/8660A210-E9E9-443D-A78F-178887B9A403_zpsfpc9m7iv.jpg.html)

Title: Re: Project Starts - Turbo
Post by: benh999 on July 31, 2014, 06:43:30 pm

Who did your engine work??

Title: Re: Project Starts - Turbo
Post by: xrrich on November 21, 2014, 06:08:50 pm

Quote from: benh999 on July 31, 2014, 06:43:30 pm

Who did your engine work??

I had the engine boring done at WARDS Engineering in Rugby

so i haven't updated in a little while....

The engine is built, and it is so much fun to drive! Here are a few more photos of the build

(http://i32.photobucket.com/albums/d30/laluk_22/IMG_2778_zps148c43b5.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_2778_zps148c43b5.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_2799_zpsd803aebe.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_2799_zpsd803aebe.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_2800_zps883e722d.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_2800_zps883e722d.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_2803_zps9d6704d1.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_2803_zps9d6704d1.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_2802_zps2dfc2b2d.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_2802_zps2dfc2b2d.jpg.html)


I got some 315cc injecters and had them cleaned just for piece of mind, and purchased a new map sensor for my spare ECU, i ran it on a safe chip whilst i ran it in, and booked myself in for a custom map with the man himself Andy

(http://i32.photobucket.com/albums/d30/laluk_22/IMG_3746_zps79679a91.png) (http://s32.photobucket.com/user/laluk_22/media/IMG_3746_zps79679a91.png.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_3618_zps72ef7400.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_3618_zps72ef7400.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_3598_zps6aa498a7.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_3598_zps6aa498a7.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_3657_zps791fa686.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_3657_zps791fa686.jpg.html)


Well i treated myself and bought some gauges so i can keep and eye worry about things aha
I was unsure where to put them at first but my switches were falling out and never fit properly because of the shitty electric windows install by previous owner, so i got chopping and sorted the wiring whilst i was there!
Luckily i had an old dash lying about that was knackered so i chopped it up to get a panel that matches the dash.
I also re located the electric windows switches.

(http://i32.photobucket.com/albums/d30/laluk_22/IMG_3819_zpsd165624c.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_3819_zpsd165624c.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_3827_zps985a7cb5.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_3827_zps985a7cb5.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_2966_zpsb9a891c0.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_2966_zpsb9a891c0.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_3829_zpsc7e6dea8.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_3829_zpsc7e6dea8.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/Mobile%20Uploads/C50049E6-B7C3-4C3A-89C1-BF34C64CA505_zpslrgstmyc.jpg) (http://s32.photobucket.com/user/laluk_22/media/Mobile%20Uploads/C50049E6-B7C3-4C3A-89C1-BF34C64CA505_zpslrgstmyc.jpg.html)


(http://i32.photobucket.com/albums/d30/laluk_22/IMG_3840_zps8f1a3554.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_3840_zps8f1a3554.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_3841_zpsa429c7c4.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_3841_zpsa429c7c4.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_3842_zpsef3525ba.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_3842_zpsef3525ba.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_3843_zps25ffa3bc.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_3843_zps25ffa3bc.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_3844_zpsf2f9eae9.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_3844_zpsf2f9eae9.jpg.html)
(http://i32.photobucket.com/albums/d30/laluk_22/IMG_3846_zpsf5a60086.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_3846_zpsf5a60086.jpg.html)

This is it as we stand today..looking like a shed!
i have put the 13's on the front because my tyres on the 15s were illeagal and i have some new wheels to go on in the next couple of weeks.

(http://i32.photobucket.com/albums/d30/laluk_22/IMG_3702_zpsd377c96c.jpg) (http://s32.photobucket.com/user/laluk_22/media/IMG_3702_zpsd377c96c.jpg.html)


Whats next?

Basically the car is a mess to drive, suspension,tracking, wheels are all over the place so i want to get it set up so i can actually drive it hard without feeling the car is going to kill me

• Sort out the rear end damage (unfortunately the rear panel has been previously repaired to a shit standard so looks quite bad behind the bumper)
• Sort new wheels
• Shocks and springs as oppose to coilovers
• Sort tracking handling etc
• Rebuild turbo (smokey on startup)

Rich

Title: Re: Project Starts - Turbo
Post by: AdzCM on November 24, 2014, 06:32:26 pm

Brilliant work mate. Really like the electric window buttons install :) really nice [I assume they're electric windows?]

Adrian

Title: Re: Project Starts - Turbo
Post by: xrrich on November 24, 2014, 09:47:36 pm

Thanks mate, yeah electric windows :) yeah it looks more factory from where there were located before

Title: Re: Project Starts - Turbo
Post by: Alexiskayak_7 on December 14, 2014, 08:10:26 pm

Where did you found those power windows from? (from what car?)

Title: Re: Project Starts - Turbo
Post by: xrrich on December 14, 2014, 09:20:13 pm

They were on the car when I bought it, think there from a golf