Help !!! Killed the Scoob !
21 November 2009, 10:55 PM
#241
Cheers, unfortunately got busy at work the last few days (shouldn't complain, pays the bills) so not done any more.
I could go in tomorrow but officially I can't work on it on a ramp with no one else there (health and safety)
I have waited this long so I suppose I can wait another week !
I could go in tomorrow but officially I can't work on it on a ramp with no one else there (health and safety)
I have waited this long so I suppose I can wait another week !
24 November 2009, 10:27 PM
#242
Managed to get a couple of hours in today, refitted the downpipe, bottom half of the airbox and lambda sensor (?) on the exhaust manifold.
Exhaust centre section, intercooler and radiator to go !
Starting to get nervous now !
Just hope the ****ing thing runs.
Exhaust centre section, intercooler and radiator to go !
Starting to get nervous now !
Just hope the ****ing thing runs.
26 November 2009, 12:49 AM
#244
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Just like to say massive respect fella
, i've just read though this thread and I can't believe how much bad luck you've had. Just goes to show how many t****rs there are working in car garages claiming 2 know what they're doing!! I describe these guys as fitters, not mechanics which sounds just like what you've had happen to ya. My scooby is runnin poo on tick over at the mo an i had to fit a new rad yesterday too but seems like a walk in the park compared to what you've been though!!.. no offence!! Anyway hope you get it all sorted fingers crossed and good luck to ya!!
, i've just read though this thread and I can't believe how much bad luck you've had. Just goes to show how many t****rs there are working in car garages claiming 2 know what they're doing!! I describe these guys as fitters, not mechanics which sounds just like what you've had happen to ya. My scooby is runnin poo on tick over at the mo an i had to fit a new rad yesterday too but seems like a walk in the park compared to what you've been though!!.. no offence!! Anyway hope you get it all sorted fingers crossed and good luck to ya!!
26 November 2009, 09:52 PM
#245
Cheers for that !
Fitted the intercooler this afternoon (big top mount so an absolute b**t**d to fit !)
Decided to refit my cone filter instead of the 'Green' panel filter.
I have butchered a spare airbox lid so that it is shielded from warm air and I now have two cold air feeds from the inner wing and one from the modified air intake at the front of the bonnet.
Short staffed tomorrow so Saturday looks like D-Day !
Oil and water, refit the battery and throttle cable and then 'Cover me, I'm going in !'
Please cross your collective fingers and toes for Saturday afternoon !
Fitted the intercooler this afternoon (big top mount so an absolute b**t**d to fit !)
Decided to refit my cone filter instead of the 'Green' panel filter.
I have butchered a spare airbox lid so that it is shielded from warm air and I now have two cold air feeds from the inner wing and one from the modified air intake at the front of the bonnet.
Short staffed tomorrow so Saturday looks like D-Day !
Oil and water, refit the battery and throttle cable and then 'Cover me, I'm going in !'
Please cross your collective fingers and toes for Saturday afternoon !
26 November 2009, 10:29 PM
#246
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What can be said
I've just read the whole story in one hit
Their will be smoke when it starts, but as long as it's quiet.
Good luck.
I'm deffo goin to log in sat night to see how it goes.
I too wish I'd not gone to one of the internet "replacement engine specialists"..
Had 3 engines in all. heading to the courts as we speak.
But at least I have had a decent mechanic on my side all the way.
But my car is still off the road.
All the best and fingers crossed for you.
Phill
I've just read the whole story in one hit
Their will be smoke when it starts, but as long as it's quiet.
Good luck.
I'm deffo goin to log in sat night to see how it goes.
I too wish I'd not gone to one of the internet "replacement engine specialists"..
Had 3 engines in all. heading to the courts as we speak.
But at least I have had a decent mechanic on my side all the way.
But my car is still off the road.
All the best and fingers crossed for you.
Phill
27 November 2009, 09:44 PM
#249
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yes.. best with spark plugs out..
I actually find they prime easier for the very first time if you don't fill the oil filter before hand.. on a normal oil change prefill the filter.
Simon
I actually find they prime easier for the very first time if you don't fill the oil filter before hand.. on a normal oil change prefill the filter.
Simon
27 November 2009, 11:49 PM
#251
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less load on the bearings as no compression and engine spins over quicker so oil pressure comes up easier.
you need the right length extention and then remove washer bottle and air filter (depends on filter fitted) to allow access.
Simon
you need the right length extention and then remove washer bottle and air filter (depends on filter fitted) to allow access.
Simon
28 November 2009, 09:32 PM
#252
Went into work this morning and fitted the battery, filled up with coolant and oil.
All fine at this point, disconnected the crank sensor and turned it over until the oil pressure warning light went out.
Now for the moment of truth............................................. .............................
Started first turn of the key !
Simples !
Or so I thought........................................... .................................................
My suspicions were first alerted to a potential problem by the fact that I was standing in a sizeable pool of pink water !
After spending ages messing about trying to discover the source of the water leak, I finally bit the bullet and removed the intercooler to get a better view.
A pinhole in the metal coolant pipe that curves under the body of the turbo !
A swine to remove with the turbo in place due to the 8mm bolt which was a pain to get to with any kind of sensible tool.
I have the water pipes from the old turbo at home so guess what I am doing with my Sunday ? (again FFS !)
Did not get to drive it but sounded fine (famous last words !)
It hits the road tomorrow if all goes according to plan !
All fine at this point, disconnected the crank sensor and turned it over until the oil pressure warning light went out.
Now for the moment of truth............................................. .............................
Started first turn of the key !
Simples !
Or so I thought........................................... .................................................
My suspicions were first alerted to a potential problem by the fact that I was standing in a sizeable pool of pink water !
After spending ages messing about trying to discover the source of the water leak, I finally bit the bullet and removed the intercooler to get a better view.
A pinhole in the metal coolant pipe that curves under the body of the turbo !
A swine to remove with the turbo in place due to the 8mm bolt which was a pain to get to with any kind of sensible tool.
I have the water pipes from the old turbo at home so guess what I am doing with my Sunday ? (again FFS !)
Did not get to drive it but sounded fine (famous last words !)
It hits the road tomorrow if all goes according to plan !
28 November 2009, 11:15 PM
#255
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Congrats, this thread is way better than any soap on the telly, more villains and crooks than Eastenders....
Good luck for Sunday !
dunx
Good luck for Sunday !
dunx
28 November 2009, 11:43 PM
#256
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I have up most respect to you and for enduring through this, I have just read through the whole thread and you could replace a years worth of TV soaps with it. I am glad you are at the point of completion and fingers crossed
29 November 2009, 11:19 AM
#258
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After all the blood , sweat, money and tears....... this thread better have a happy ending .... along the lines of ...... the Scooby revved happily ever after lol
29 November 2009, 01:04 PM
#259
Looks like your (HUUUUGE) efforts are going to be rewarded! 
I have everything crossed for you... Have you fitted that coolant pipe yet?!... Is it running like a well oiled sewing machine?!... C'mon! The suspense is killing me, lol.
I have everything crossed for you... Have you fitted that coolant pipe yet?!... Is it running like a well oiled sewing machine?!... C'mon! The suspense is killing me, lol.
Last edited by joz8968; 29 November 2009 at 01:05 PM.
29 November 2009, 09:50 PM
#260
Thanks fellas, I have to say that I am honestly touched by all the encouragement and advice that has been offered.
I went in today armed with the coolant pipes from the old turbo, the car has a VF35 fitted now so the pipes from the TD04 needed a minor 'adjustment'.
The two pipes are joined together by a thin metal strip to get the correct spacing for the holes on the turbo, the TD04 holes are closer together than the VF35 ones so the metal strip had to go.
A little bit of 'bending and 'hey presto' it snaps apart, bench grinder took care of the sharp edges and as a bonus, sorted out my finger nails as well !
Made sure I had copper washers either side of the bolt and tightened it all up.
So far, so good.
I then had to do battle with my intercooler, it came from Scoobyclinic but it is one of the huge 'ebay / XS power' type top mounts.
I really dread removing it because it is a total b*st**d to refit.
It's taller, deeper and wider than even the STi one so it really is a tight squeeze, especially since I have a front strut brace as well.
Add to this, wrestling the pipe onto the turbo outlet, the intercooler outlet onto the throttle body, trying to line up the modified brackets and keep the equally oversized Turbosmart dump valve out of the way ! No wonder I get stressed.
On the plus side, by the time I had got it fitted, the IOU's in the swear box could fund a forged 2.5 and six speed conversion !
Topped up the coolant for round two and fired it up, reversed it so the exhaust was pointing outside and left it running whilst monitoring the temperature.
All going well until I noticed wet feet again but this time coolant all over the top of the header tank !
First thought was 'did I fit the cap properly ? or could the cap be faulty ?'
Being possesed of an enquiring mind, a healthy dose of good old fashioned stupidity and no regard for my personal wellbeing, I went for the hands on approach and wiggled the coolant pipe from the turbo to the header tank.
Fantastic !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
Tiny split in the hose now really gets into its stride, showering me with red hot water / coolant mix in the process.
I understand now why McDonalds haven't added it to their list of hot beverages.
Something about the bitter aftertaste left by the anti freeze I guess ?
Once I could see again and got rid of most of the antifreeze in my mouth, I was faced with a dilemma.
The pipe was only just long enough anyway so I couldn't cut the damaged part off, the only hoses I had around did not look up to the job (walls too thin and no reinforcement), the famous 'blue hosepipe' as fitted by the monkeys up the road was not really an option, what was I to do ?
Bearing in mind it's now gone 3pm on a Sunday !
I had to lock and alarm the building and dash to the motor factors down the road, the fact that he was open was a good start.
I had the the old hose as a sample, the only thing even close was reinforced fuel line.
First problem, he doesn't take cards and like the Queen, I don't 'do' cash !
I was ready to buy other bits just to get to a worthwhile total but no credit or debit card facility at all.
He eventually sells me a short length of hose for £1 (all I had in change !)
Right !
Back to the dealership, unlock and disable the alarms, spend an entertaining 10 minutes trying to persuade the hose to fit.
Inner diameter just too narrow, in desperation I decide to 'chamfer' the inner hose with a particularly sharp stanley knife (memo to self, obey the Doctors instruction to keep me away from sharp implements)
When I regained consiousness (excessive, rapid blood loss can have this effect), I decided to resort to plan 'B'.
A trip to Halfords !
Should just be time before they close ?
So, lock and alarm the f**k**g building again and leap into the trusty company car (59 plate BMW 318i, don't get me started on that either, Jaguar dealership and they put us in BMW's ? 24,000 miles per year and they give me a petrol ?)
Arrive at Halfords and try to locate suitable hose, 10mm fuel hose, garden hose, every other kind of hose know to man but no visible coolant hose !
In desperation, I went to the parts counter and joined a small commune of disgruntled customers, all waiting for some signs of intelligent life from behind the counter !
Civilisations rose and fell whilst I waited but eventually I got served.
From the assistants facial expression, things were not looking good for Mrs Greenwoods boy, but then, behold !
He found a coil of hose in a box behind the counter and sold me a metre (never let it be said that I ever overestimate the materials required) for a very reasonable two of your earth pounds (and they take cards !)
Another dash to the dealership, unlock, disable alarm, etc, etc..........................
Fitted the new section of hose (seemed to have about 85cm spare ? can't think why !)
More water, start it up and run up to temperature, turn heater control up and down a few times, squeeze the hoses and so on.
All looked okay so decided to take it for a road test...........................................
Yeah baby!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!
Didn't realise how much I had missed the old thing !
Took it steady but opened it up on the slip road to the local dual carriageway, what a rush !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!
Because the last engine was supposedly reconditioned, I had to drive it gently to run it in.
The VF35 and pink injectors were fitted at the same time so never driven the car in anger with them fitted.
The noise from the modified induction sounds awesome, the flat four soundtrack is better than ever.
Bearing in mind that the ECU map was done with low boost for the running in process, the car feels quick (could just be that I have been driving slow ar*e cr*p for the past few months)
I can't wait to get the map 'tweaked' !
Provided that I don't blow it up again !
Just got to regass the aircon and then I can start thinking about getting it clean and shiny again.
I went in today armed with the coolant pipes from the old turbo, the car has a VF35 fitted now so the pipes from the TD04 needed a minor 'adjustment'.
The two pipes are joined together by a thin metal strip to get the correct spacing for the holes on the turbo, the TD04 holes are closer together than the VF35 ones so the metal strip had to go.
A little bit of 'bending and 'hey presto' it snaps apart, bench grinder took care of the sharp edges and as a bonus, sorted out my finger nails as well !
Made sure I had copper washers either side of the bolt and tightened it all up.
So far, so good.
I then had to do battle with my intercooler, it came from Scoobyclinic but it is one of the huge 'ebay / XS power' type top mounts.
I really dread removing it because it is a total b*st**d to refit.
It's taller, deeper and wider than even the STi one so it really is a tight squeeze, especially since I have a front strut brace as well.
Add to this, wrestling the pipe onto the turbo outlet, the intercooler outlet onto the throttle body, trying to line up the modified brackets and keep the equally oversized Turbosmart dump valve out of the way ! No wonder I get stressed.
On the plus side, by the time I had got it fitted, the IOU's in the swear box could fund a forged 2.5 and six speed conversion !
Topped up the coolant for round two and fired it up, reversed it so the exhaust was pointing outside and left it running whilst monitoring the temperature.
All going well until I noticed wet feet again but this time coolant all over the top of the header tank !
First thought was 'did I fit the cap properly ? or could the cap be faulty ?'
Being possesed of an enquiring mind, a healthy dose of good old fashioned stupidity and no regard for my personal wellbeing, I went for the hands on approach and wiggled the coolant pipe from the turbo to the header tank.
Fantastic !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
Tiny split in the hose now really gets into its stride, showering me with red hot water / coolant mix in the process.
I understand now why McDonalds haven't added it to their list of hot beverages.
Something about the bitter aftertaste left by the anti freeze I guess ?
Once I could see again and got rid of most of the antifreeze in my mouth, I was faced with a dilemma.
The pipe was only just long enough anyway so I couldn't cut the damaged part off, the only hoses I had around did not look up to the job (walls too thin and no reinforcement), the famous 'blue hosepipe' as fitted by the monkeys up the road was not really an option, what was I to do ?
Bearing in mind it's now gone 3pm on a Sunday !
I had to lock and alarm the building and dash to the motor factors down the road, the fact that he was open was a good start.
I had the the old hose as a sample, the only thing even close was reinforced fuel line.
First problem, he doesn't take cards and like the Queen, I don't 'do' cash !
I was ready to buy other bits just to get to a worthwhile total but no credit or debit card facility at all.
He eventually sells me a short length of hose for £1 (all I had in change !)
Right !
Back to the dealership, unlock and disable the alarms, spend an entertaining 10 minutes trying to persuade the hose to fit.
Inner diameter just too narrow, in desperation I decide to 'chamfer' the inner hose with a particularly sharp stanley knife (memo to self, obey the Doctors instruction to keep me away from sharp implements)
When I regained consiousness (excessive, rapid blood loss can have this effect), I decided to resort to plan 'B'.
A trip to Halfords !
Should just be time before they close ?
So, lock and alarm the f**k**g building again and leap into the trusty company car (59 plate BMW 318i, don't get me started on that either, Jaguar dealership and they put us in BMW's ? 24,000 miles per year and they give me a petrol ?)
Arrive at Halfords and try to locate suitable hose, 10mm fuel hose, garden hose, every other kind of hose know to man but no visible coolant hose !
In desperation, I went to the parts counter and joined a small commune of disgruntled customers, all waiting for some signs of intelligent life from behind the counter !
Civilisations rose and fell whilst I waited but eventually I got served.
From the assistants facial expression, things were not looking good for Mrs Greenwoods boy, but then, behold !
He found a coil of hose in a box behind the counter and sold me a metre (never let it be said that I ever overestimate the materials required) for a very reasonable two of your earth pounds (and they take cards !)
Another dash to the dealership, unlock, disable alarm, etc, etc..........................
Fitted the new section of hose (seemed to have about 85cm spare ? can't think why !)
More water, start it up and run up to temperature, turn heater control up and down a few times, squeeze the hoses and so on.
All looked okay so decided to take it for a road test...........................................
Yeah baby!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!
Didn't realise how much I had missed the old thing !
Took it steady but opened it up on the slip road to the local dual carriageway, what a rush !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!
Because the last engine was supposedly reconditioned, I had to drive it gently to run it in.
The VF35 and pink injectors were fitted at the same time so never driven the car in anger with them fitted.
The noise from the modified induction sounds awesome, the flat four soundtrack is better than ever.
Bearing in mind that the ECU map was done with low boost for the running in process, the car feels quick (could just be that I have been driving slow ar*e cr*p for the past few months)
I can't wait to get the map 'tweaked' !
Provided that I don't blow it up again !
Just got to regass the aircon and then I can start thinking about getting it clean and shiny again.
29 November 2009, 10:02 PM
#261
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Brillaint news a long hard battle that looks like it has been won. I love your write up as well had me in stitches and I must admire your humour after all that has happened, have you ever thought of becoming a writer 
Well Done Mate
29 November 2009, 10:12 PM
#262
Thank you !
If I had lost my sense of humour, I would have had a breakdown before now with everything that has happened !
I would love to be a writer, but Stephen King seems to have cornered the market with 'Christine' LOL
As a famous man once said ' I started off with nothing and I still have most of it left'
If I had lost my sense of humour, I would have had a breakdown before now with everything that has happened !
I would love to be a writer, but Stephen King seems to have cornered the market with 'Christine' LOL
As a famous man once said ' I started off with nothing and I still have most of it left'
30 November 2009, 01:37 AM
#263
My thoughts exactly - Richard Curtis/Ben Elton can't hold a candle to your writng lol 
Great news and amazing determination.
NOW my lad... just make sure you run it in properly and DO NOT!!! be provoked into any "red mist"-based duels until after 750-1000m have passed!...
Great news and amazing determination.
NOW my lad... just make sure you run it in properly and DO NOT!!! be provoked into any "red mist"-based duels until after 750-1000m have passed!...
30 November 2009, 01:16 PM
#264
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Yeah ! success !
Nice one, now read up on running in techniques, don't hold at constant revs, no excessive load, and no over-revving....
dunx
Nice one, now read up on running in techniques, don't hold at constant revs, no excessive load, and no over-revving....
dunx
30 November 2009, 09:11 PM
#267
Thanks for the kind words guys !
Simon did the 'running in' remap straight after the 'supposedly' reconditioned engine was fitted, the VF35 and pinks went on at the same time.
I hope that I am safe with the current map ?
My theory being that it is set up for the turbo, injectors and all the other mods, just set for lower maximum boost ?
The current plan is to run it for a while and if it doesn't blow up, throw a rod, overheat, underheat, experience a warp core breach or cause the end of civilisation as we know it, get Simon to tweak the map for more boost.
mmmmmmmmmmmmmmmm.................................. ...................more boost............................................. ..........................
Or alternatively, I could strip some of the tuning bits and do a deal with the 2002 STi that is for sale on here ?
Nurse, my medication please............................................ ..................................
Simon did the 'running in' remap straight after the 'supposedly' reconditioned engine was fitted, the VF35 and pinks went on at the same time.
I hope that I am safe with the current map ?
My theory being that it is set up for the turbo, injectors and all the other mods, just set for lower maximum boost ?
The current plan is to run it for a while and if it doesn't blow up, throw a rod, overheat, underheat, experience a warp core breach or cause the end of civilisation as we know it, get Simon to tweak the map for more boost.
mmmmmmmmmmmmmmmm.................................. ...................more boost............................................. ..........................
Or alternatively, I could strip some of the tuning bits and do a deal with the 2002 STi that is for sale on here ?
Nurse, my medication please............................................ ..................................
30 November 2009, 10:12 PM
#268
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it is running fairly low boost but was setup on what turned out to be that rubbish bottom end (was not happy with that one when I heard it in the detcans) but has safe ignition.. just try and avoid heavy right foot.
Simon
Simon
