Project Starts - Turbo

[xrrich]

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

£56 plus VAT and Carriage

[xrrich]

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



And she is back together





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?

[xrrich]

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








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!






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

[z3i]

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

[xrrich]

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!!

[JoeH]

What mileage is the engine at?

[xrrich]

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

[Snave]

good luck for the rebuild !

[xrrich]

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







So work has been slow on mine but .....
The engine has been built!!!!  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




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.





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







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

[benh999]

Who did your engine work??

[xrrich]

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








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







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.















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.




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

[AdzCM]

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

Adrian

[xrrich]

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

[Alexiskayak_7]

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

[xrrich]

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