Turbo Engine Rebuild
- Thread starter scam75
- Start date
scam75
Well-known member
Update from today - she runs!!
The day started off with the front end built up, coolant filled, and ready to start up. She did, but immediately died. Thanks again to Martin and Eldavo for giving me some of their time as we went through the trouble shooting process. The usual stuff, DME relay, bypass DME relay, speed and ref sensors, check for fuel, check for spark, smoke test to check for air leaks to name a few. None of this led us anywhere although the consensus was an electrical issue somewhere. So after some poking around the MAF area we noticed the MAF plug had a wire popped back in the multi-plug (all aftermarket as I have a SciVision). Anyway, we got this wire back where it should be, turned the key and off she went much to the delight of both of us!
Next job before running up to temp was to replace the 2 x washers on the turbo oil return to sump pipe. A messy job and a litre of fresh mineral oil perished in the process. Anyway it was time to start her up again and run up to temp for the first time, and check for leaks, issues etc. I am pleased to report she ran great up to temperature and is air tight, water tight and oil tight! The beer this evening will taste sweet!
So looking at Sunday now for the next installment. Gearbox back in, exhaust on, proper fix on the MAF wiring, nose panel back on, PS belt on, check belt tensions, belt covers, adapt the wiring for the new turbo aux water pump, alternator cooling duct and a few other bits and bobs before the undertrays go back on.
Next week then at the latest I can begin the running in process! Meant to add engine sounded good, but with the exhaust from turbo back not on, it was a tad noisy to hear everything. All seemed to be in good order in terms of the engine rebuild though. Happy bunny today!
Stuart
The day started off with the front end built up, coolant filled, and ready to start up. She did, but immediately died. Thanks again to Martin and Eldavo for giving me some of their time as we went through the trouble shooting process. The usual stuff, DME relay, bypass DME relay, speed and ref sensors, check for fuel, check for spark, smoke test to check for air leaks to name a few. None of this led us anywhere although the consensus was an electrical issue somewhere. So after some poking around the MAF area we noticed the MAF plug had a wire popped back in the multi-plug (all aftermarket as I have a SciVision). Anyway, we got this wire back where it should be, turned the key and off she went much to the delight of both of us!
Next job before running up to temp was to replace the 2 x washers on the turbo oil return to sump pipe. A messy job and a litre of fresh mineral oil perished in the process. Anyway it was time to start her up again and run up to temp for the first time, and check for leaks, issues etc. I am pleased to report she ran great up to temperature and is air tight, water tight and oil tight! The beer this evening will taste sweet!
So looking at Sunday now for the next installment. Gearbox back in, exhaust on, proper fix on the MAF wiring, nose panel back on, PS belt on, check belt tensions, belt covers, adapt the wiring for the new turbo aux water pump, alternator cooling duct and a few other bits and bobs before the undertrays go back on.
Next week then at the latest I can begin the running in process! Meant to add engine sounded good, but with the exhaust from turbo back not on, it was a tad noisy to hear everything. All seemed to be in good order in terms of the engine rebuild though. Happy bunny today!
Stuart
scam75
Well-known member
Thanks lads!
Yeah Dan, 4 years, that's a lifetime! I'm off the road a year now and with the car being 25 miles away at my mates place, I quite often have genuinely forgotten I own the thing! Was great to sit in the car and hold the revs at 2k today, and monitor all the dials, feel the heaters get hot etc. while my mate was doing all his inspections underneath. Even better when he confirmed nothing was leaking anywhere after all the stuff we've had to deal with. It is starting to feel real again!
Worth mentioning the 1.7KW starter (though as noted an inch longer than the old one, leaving the heat shield an inch short) is an absolute beast compared to the old one. Super strong and quick.
Glad you've been busy, be great to get yours running soon!
Stuart
Yeah Dan, 4 years, that's a lifetime! I'm off the road a year now and with the car being 25 miles away at my mates place, I quite often have genuinely forgotten I own the thing! Was great to sit in the car and hold the revs at 2k today, and monitor all the dials, feel the heaters get hot etc. while my mate was doing all his inspections underneath. Even better when he confirmed nothing was leaking anywhere after all the stuff we've had to deal with. It is starting to feel real again!
Worth mentioning the 1.7KW starter (though as noted an inch longer than the old one, leaving the heat shield an inch short) is an absolute beast compared to the old one. Super strong and quick.
Glad you've been busy, be great to get yours running soon!
Stuart
Dan944t
New member
scam75 said:
cor yea i bet that felt great mate!…. i honestly can’t wait to hear it alive again , i left it too long this time . i even love the smell of it inside it’s amaizing! [
] im so close now and i’m considering buying the vems kit soonish [8|] well see maybe once alls good and up and running well again…
looking forward to hearing how yours goes and i bet it’s now torchurous but so exciting knowing you’ll be back in it soon [
]
scam75
Well-known member
Some more progress, inching closer!
Turbo aux water pump wiring is done. MAF wiring fixed properly. Gearbox and cooler back on and topped up. More heat shields and bits and bobs done.
Still to do: refit exhaust, run up to temp again, tension belts, front covers back on, PS belt, full check over, undertrays, MOT.
Mate says weekend or early next week for it be ready. Ironically I go in for knee op on Tuesday (just a clean up, cartlidge and stuff) and probably won't be able to drive for a couple of weeks! [8|]
Hopefully have it back on the drive for Monday and after a very long drive I can polish it for weeks whilst limping about! []
Stuart
Turbo aux water pump wiring is done. MAF wiring fixed properly. Gearbox and cooler back on and topped up. More heat shields and bits and bobs done.
Still to do: refit exhaust, run up to temp again, tension belts, front covers back on, PS belt, full check over, undertrays, MOT.
Mate says weekend or early next week for it be ready. Ironically I go in for knee op on Tuesday (just a clean up, cartlidge and stuff) and probably won't be able to drive for a couple of weeks! [8|]
Hopefully have it back on the drive for Monday and after a very long drive I can polish it for weeks whilst limping about! [
]Stuart
Dan944t
New member
scam75 said:Some more progress, inching closer!
Turbo aux water pump wiring is done. MAF wiring fixed properly. Gearbox and cooler back on and topped up. More heat shields and bits and bobs done.
Still to do: refit exhaust, run up to temp again, tension belts, front covers back on, PS belt, full check over, undertrays, MOT.
Mate says weekend or early next week for it be ready. Ironically I go in for knee op on Tuesday (just a clean up, cartlidge and stuff) and probably won't be able to drive for a couple of weeks! [8|]
Hopefully have it back on the drive for Monday and after a very long drive I can polish it for weeks whilst limping about! [
Stuart
this is fantastic new Stu![
]not long now at all mate ….
best of luck with the knee op and wish u fast recovery so u can enjoy ur car again soon !….
im starting to get close to finishing mine too now ( what allot of graft it’s been though fabricating the lot from scratch,.. but i’ve fabricated the entire 3” exhuast from my new holset all way back and made my own rear box with tailpipe from my old one. and all the twin scroll from down pipes to turbo and back to wastegate done! all that’s left to fabricate my screamer pipe from wastegate as i’m not longer having it plumed into the exhuast for better flow,…..and then all the fabricating of my intercooler pipes ect ect ect will commence in t engine bay along with belts ect - …..i’m getting there though as are u [
]Dan
scam75
Well-known member
Well turns out my mate was working today, waited till 8pm to phone me to tell me its ready, as he thought my op was today! MOT with no advisories and just needing run in, unfortunately my knee needs run in first but hey ho, its ready and she lives!!
See how I am later in the week.
Cheers
Stuart
See how I am later in the week.
Cheers
Stuart
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