DIY 450 bhp Classic 2.0L
15 June 2006, 02:08 PM
#271
Andrew,
The Power FC is still in its box in the house!! The O2 sensor is fecked. But Andy took this into account last time he mapped it so I presume the Ecutek is running in open loop mode at the mo.
What is the stock fuel pressure I presume its circa 3bar at idle with vacuum hose off??
The Power FC is still in its box in the house!! The O2 sensor is fecked. But Andy took this into account last time he mapped it so I presume the Ecutek is running in open loop mode at the mo.
What is the stock fuel pressure I presume its circa 3bar at idle with vacuum hose off??
Last edited by dazdavies; 15 June 2006 at 03:51 PM.
17 June 2006, 11:48 PM
#272
Very busy day today indeed.
It started with the arrival of this at 11 am this morning:
http://www.scoob.co.uk/rebuild/fullkit.jpg
http://www.scoob.co.uk/rebuild/fmicinbox.jpg
http://www.scoob.co.uk/rebuild/pipingkit.jpg
Very pleasently surpised by the quality of this kit. I phoned up and ordered it yesterday afternoon and it was here today. £368 including vat and next day saturday delivery from a company in Northen Ireland. Very friendly bloke and excellent service. Autospares of comber 0289 1871199
After unpacking it all the Car was quickly reduced to this:
http://www.scoob.co.uk/rebuild/bumperremoved.jpg
It was easier than I thought too:
Lights out, 5 screws and clips across the top.
1 10 mm bolt in the middle at the front.
2 17 mm bolts underneath
then with both wheel arch liners removed there were two more screws and clips 1 on either side. The bumper came off and took 20 minutes from start to finish.
From the centre point i measured 250mm one way and then 250 mm the other and drilled two 6mm holes one on either side at the 250mm points.
This allowed for the bolts to hold the intercooler to the bumber support beam that runs acroos the car at the front.
The intercooler was then bolted into place ready for pipework fitting.
http://www.scoob.co.uk/rebuild/intercoolernobumper.jpg
Pipework went in ok, a bit fiddly and a bit tight in places but otherwise ok.
Had to cut the bumper. quite alot to cut away. Here's what I had to cut off:
http://www.scoob.co.uk/rebuild/bumperoffcuts.jpg
With the bumper back on.
http://www.scoob.co.uk/rebuild/fromfront.jpg
Almost finished. As you can see from the pick I need to adapth the pipework slightly as the APS cold air feed gets in the way but I want to keep this so will get some pipework knocked up during the week.
http://www.scoob.co.uk/rebuild/almostfinished2.jpg
http://www.scoob.co.uk/rebuild/almostfinished1.jpg
Home straight now. I have decided to get it run in using a standard turbo for the time being. So all I need now is a decent VF28 (really wish I hadn't sold mine now
), a crank shaft position sensor (broke my existing one taking it out of the old pump) and a new alternator or atleast a decent second hand one. If anyone has any of these parts knocking about and is willing to part with them please let me know 
. SX fuel pressure regulator should be arriving tuesday. So not long now before I fire her up for the first time in six months with a new engine!!!! I'm getting excited by the prospect.
Cheers
Daz
It started with the arrival of this at 11 am this morning:
http://www.scoob.co.uk/rebuild/fullkit.jpg
http://www.scoob.co.uk/rebuild/fmicinbox.jpg
http://www.scoob.co.uk/rebuild/pipingkit.jpg
Very pleasently surpised by the quality of this kit. I phoned up and ordered it yesterday afternoon and it was here today. £368 including vat and next day saturday delivery from a company in Northen Ireland. Very friendly bloke and excellent service. Autospares of comber 0289 1871199
After unpacking it all the Car was quickly reduced to this:
http://www.scoob.co.uk/rebuild/bumperremoved.jpg
It was easier than I thought too:
Lights out, 5 screws and clips across the top.
1 10 mm bolt in the middle at the front.
2 17 mm bolts underneath
then with both wheel arch liners removed there were two more screws and clips 1 on either side. The bumper came off and took 20 minutes from start to finish.
From the centre point i measured 250mm one way and then 250 mm the other and drilled two 6mm holes one on either side at the 250mm points.
This allowed for the bolts to hold the intercooler to the bumber support beam that runs acroos the car at the front.
The intercooler was then bolted into place ready for pipework fitting.
http://www.scoob.co.uk/rebuild/intercoolernobumper.jpg
Pipework went in ok, a bit fiddly and a bit tight in places but otherwise ok.
Had to cut the bumper. quite alot to cut away. Here's what I had to cut off:
http://www.scoob.co.uk/rebuild/bumperoffcuts.jpg
With the bumper back on.
http://www.scoob.co.uk/rebuild/fromfront.jpg
Almost finished. As you can see from the pick I need to adapth the pipework slightly as the APS cold air feed gets in the way but I want to keep this so will get some pipework knocked up during the week.
http://www.scoob.co.uk/rebuild/almostfinished2.jpg
http://www.scoob.co.uk/rebuild/almostfinished1.jpg
Home straight now. I have decided to get it run in using a standard turbo for the time being. So all I need now is a decent VF28 (really wish I hadn't sold mine now
), a crank shaft position sensor (broke my existing one taking it out of the old pump) and a new alternator or atleast a decent second hand one. If anyone has any of these parts knocking about and is willing to part with them please let me know . SX fuel pressure regulator should be arriving tuesday. So not long now before I fire her up for the first time in six months with a new engine!!!! I'm getting excited by the prospect.Cheers
Daz
Last edited by dazdavies; 18 June 2006 at 02:14 PM.
18 June 2006, 08:02 AM
#274
You did well to do all that yesterday in the heat!
I'm impressed with the fit of the 'cold' pipe past the battery, wish mine was that low past the battery.
Good progress!
Graham
I'm impressed with the fit of the 'cold' pipe past the battery, wish mine was that low past the battery.
Good progress!
Graham
18 June 2006, 07:31 PM
#275
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I have a VF28 Daz. Run it in with it then just give it me back afterwards. Im in Hinckley area of Leicestershire
19 June 2006, 11:40 PM
#278
Just thought I'd say a big public thankyou to P1Mark for his generosity and leap of faith in lending me his VF28 Turbo for running my engine in.
It saves me from wasting £300 on a second hand one of which I dont know the history.
So a massive thanks. I shall return it to you and will give you first drive when the twisted setup is fitted and mapped.
ps it was great to meet you and talk to a fellow enthusiast. Your current project is way bigger than mine good luck with the house!!!
Daz
It saves me from wasting £300 on a second hand one of which I dont know the history.
So a massive thanks. I shall return it to you and will give you first drive when the twisted setup is fitted and mapped.
ps it was great to meet you and talk to a fellow enthusiast. Your current project is way bigger than mine
good luck with the house!!!Daz
20 June 2006, 06:55 AM
#279
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Cheers Daz, good to meet you and your lovely lady last night. I will take you up on that offer i feel
I fear your car will be finished a long time before my house..........
I fear your car will be finished a long time before my house..........
20 June 2006, 11:50 PM
#280
My Sx Fuel pressure Reg Turned up today.
All my hoses are -6AN and all my fittings are -6AN. was looking on demon tweeks website for some male to male fittings so I could fit the straight hose connectors into the SX fuel pressure reg.
I couldnt see a male to male -6 Connector on their site. Can somebody tell me what size I need. Is it 3/8 npt 3/8 bsp or 9/16 blah blah blah?
Cheers
Daz
All my hoses are -6AN and all my fittings are -6AN. was looking on demon tweeks website for some male to male fittings so I could fit the straight hose connectors into the SX fuel pressure reg.
I couldnt see a male to male -6 Connector on their site. Can somebody tell me what size I need. Is it 3/8 npt 3/8 bsp or 9/16 blah blah blah?
Cheers
Daz
21 June 2006, 08:19 AM
#281
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Originally Posted by dazdavies
I couldnt see a male to male -6 Connector on their site. Can somebody tell me what size I need. Is it 3/8 npt 3/8 bsp or 9/16 blah blah blah?
I've got both male/male and female/female laying around at the workshop, PM me and I'll sort them out for you.
21 June 2006, 12:18 PM
#282
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Originally Posted by 911
You did well to do all that yesterday in the heat!
I'm impressed with the fit of the 'cold' pipe past the battery, wish mine was that low past the battery.
Good progress!
Graham
I'm impressed with the fit of the 'cold' pipe past the battery, wish mine was that low past the battery.
Good progress!
Graham
This is why the bottom of Daz's IC is protruding beneath the splitter, as it sits lower allowing the pipe to sit nicer in the space behind the oil cap.
Daz needs a P1 splitter now to cover up the bottom of the intercooler
21 June 2006, 12:50 PM
#283
I'm in trouble then.
I left my bar intact and the FMIC just tucks-up under the bumper, but the top pipe is too high, acually touches the bonnet when it is closed.
Will be cut/weld it this winter to get it right. Tried repositioning the samcos/pipes/clamps to no avail.
Could always rotate the inlet!(no)
I don't have the precision you lot have.
Graham
I left my bar intact and the FMIC just tucks-up under the bumper, but the top pipe is too high, acually touches the bonnet when it is closed.
Will be cut/weld it this winter to get it right. Tried repositioning the samcos/pipes/clamps to no avail.
Could always rotate the inlet!(no)
I don't have the precision you lot have.
Graham
21 June 2006, 02:53 PM
#286
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what part of it? yours has not gone wrong has it?
crank/rods/pistons in the bin. just building the block at the moment with Billet crank/Arrow rods/omega pistons etc.
crank/rods/pistons in the bin. just building the block at the moment with Billet crank/Arrow rods/omega pistons etc.
23 June 2006, 05:29 PM
#287
HELP!!!
looks like I have an injector thats seized open. Does anyone have a spare yellow phase two 440cc within reaoabl travelling distance of the Doncaster area I can borrow or buy to test. My engine is ready to fire up but I have this fuel problem to sort before I can start it. Feel free to ring me on 07957 135404
cheers
Daz
looks like I have an injector thats seized open. Does anyone have a spare yellow phase two 440cc within reaoabl travelling distance of the Doncaster area I can borrow or buy to test. My engine is ready to fire up but I have this fuel problem to sort before I can start it. Feel free to ring me on 07957 135404
cheers
Daz
23 June 2006, 09:36 PM
#290
All sorted now. Was a leaking o-ring that resulted in hydraulic lock of the engine. This led to a failed starter motor too. Once I realised what had happened and replaced the starter it fired up first time and runs like a dream. Have a couple of leaks a water leak and what looks to be a leaking sump so I'l look at them tomorrow. Right then I'm off for a pint or ten
Daz
Daz
24 June 2006, 07:15 PM
#294
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Originally Posted by Floyd
Mark, my engine is still OK AFAIK but i thought you did a preety good job of the last one before building your next. I thought yours was OK or did it go bang?
F
F
. Just doing another that will suport more BHP as and when i feel like having it Daz - thats exactly what it sounded like not cos i was standing next to you - more the fact you rang me and put your phone to your car!
27 June 2006, 11:50 AM
#295
Right then quick update.
Got car started and it ran like a dream for 80 miles when an injector o ring failed and led to the engine cutting out and eventually leading to hydraulic lock. Being the amatuer I am I also failed to see the missing pintle cap on the end of the injector too. I took the engine out again and took off the exhaust maifold which was filled with fuel, as was the down pipe how my car never set on fire I'll never know. When this happened I tried cranking it to get it back started which has also led to a shafted flywheel managed to inspect it in situ and the bad news is I have to take the engine out again to replace a flywheel that now has several teeth missing. I'm going to go to the scrappers for now and get an OEM one as the exedy twin plate I will eventually have to get will have its own flywheel anyway. I really thought I'd screwed up a brand new engine. But when the car does start it runs well, idles perfectly and doesn't leek. So off to city auto salvage in sheffield tonight to pick up flywheel.
to be continued...
Daz
Got car started and it ran like a dream for 80 miles when an injector o ring failed and led to the engine cutting out and eventually leading to hydraulic lock. Being the amatuer I am I also failed to see the missing pintle cap on the end of the injector too. I took the engine out again and took off the exhaust maifold which was filled with fuel, as was the down pipe how my car never set on fire I'll never know. When this happened I tried cranking it to get it back started which has also led to a shafted flywheel managed to inspect it in situ and the bad news is I have to take the engine out again to replace a flywheel that now has several teeth missing. I'm going to go to the scrappers for now and get an OEM one as the exedy twin plate I will eventually have to get will have its own flywheel anyway. I really thought I'd screwed up a brand new engine. But when the car does start it runs well, idles perfectly and doesn't leek. So off to city auto salvage in sheffield tonight to pick up flywheel.
to be continued...
Daz
27 June 2006, 12:21 PM
#296
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I just hope thats all thats damaged, hydraulic lock can bend a rod...
27 June 2006, 12:35 PM
#297
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Daz, make sure you remove the plugs and crank it by hand. I would also suggest changing the oil, as it will most probably be heavily diluted with petrol.
27 June 2006, 02:38 PM
#298
Originally Posted by P20SPD
Daz, make sure you remove the plugs and crank it by hand. I would also suggest changing the oil, as it will most probably be heavily diluted with petrol.
The plugs were removed and when I cranked it by hand a boat load of fuel came out of the bore in question all the others were ok.
Oil will be changed for a third time when the engine comes out tonight following a visit to David Wallis to take him up on his kind offer of a flywheel.
Jay rods are ok as I was sat at traffic lights when it happened so thankfully it was doing no more than idle revs. It has started since with no strange noises.
27 June 2006, 10:23 PM
#300
Just like to say thanks to David Wallis for the flywheels he so kindly gave me.
Unsure which one to use as one is thicker than the other. The thicker one of the two is brand new so I am inclined to use that. Does flywheel thickness matter?
Daz
Unsure which one to use as one is thicker than the other. The thicker one of the two is brand new so I am inclined to use that. Does flywheel thickness matter?
Daz