must be one heck of a buzz when your first about to start this for the first time, bit like the excitement as a kid on xmas day after seeing santas been.
god job matey

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andrew315rawson@live.co.uk
Moonstone phase 7 gti6
My Project thread: http://www.306gti6.com/forum/showthread.php?id=119992&page=1

Probably coz youre right

every man and his dogs got one of them now

looking good

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TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread

Is that a 3" outlet/inlet on that intercooler then like the one in Midlifes clicky?

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Just Drive It

Cool Now see your using reducers to get it onto the 2.5" piping Who was it that welded the angled pipe straight onto the IC? Was that Rich?

Have you any plans for the gearbox too Matt?

Cheers

________________________________________

Just Drive It

I recognise that intercooler Wayne

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Team 375 BHP Duratec™

We've all seen the fag packet comparison

The battery was charged up, refitted, and the engine cranked over on the starter to build up oil pressure.
The PAS was leaking at the high pressure joint, which was promptly tightened and fixed.

Filling up the rad, highlighted a massive leak from the water pump.
I was very confused as I didn't think I had pinched the gasket when fitting. On removal of the water pump and inspection it looks like the gasket was not manufactured 100% correctly and the seal was slightly lower in some places than others. You'd be hard pressed to spot it though.

So I sealed up the pump gasket, refitted the pump and timed up the engine again - something I find easier with the 136 tooth belt. The rad was refilled and it seemed to be holding water ok now.

The supercharger oil circuit was hooked up and primed ready for startup.

First startup

Moment of truth:
The car turned over and over but no fuel or spark. I set about changing relays, cam, crank sensors, checking fuses and wiring, fuel cut off switch.
Speaking to Rich, he was confident that the ECU chip needed reseating. It was indeed mounted slightly too deep in its socket. Sure enough on refitting, the fuel pump primed, the car started on the key and fired into life

However...


...the engine immediately started to rev up, which I didn't fancy given the engine is on zero miles

So I set about trying to identify any air leaks, and tightened up all the boost piping and vacuum pipes. This helped a little but the car was still idling at 2.5kish. I moved onto checking the stepper, vacuum pipes and throttle assembly for leaks.

I got the idle down to a fluctuating 1-1.5k and then after more boost pipe tweaks the engine was idling nicely at 900rpm.

One of the issues I was concerned about was whether the head would tap or not (remember it was a previous snapper which was supposedly repaired without tapping. I did find a bent valve during the rebuild however). I figured if it did the head could come off get stripped down and new valve guides fitted. But all seems fine in that respect.

I discovered that the high pressure PAS pipe was still leaking a lot and I had an oil leak from what looked like the front of the sump. Looking carefully, it was actually leaking from further up the block. On removing the starter motor I traced the oil leak back to an oil gallery blanking plug, and the oil level sensor on the front of the block. Tightening these up cured the leak. The PAS leak seems to be due to a missing seal in the pipe - I must have fitted the pipe without it

With these annoying leaks fixed, and all fluids topped up, it was time to finish refitting the trim, engine mount cradle and battery box etc. The slam panel was then secured to the chassis and headlights connected back up etc.

I dropped the car back down on it's wheels to check the boost pipe clearance which was too low really.

So I cut down the pipes a little to give a bit more clearance until they can be welded up and mounted higher. Once the pipes were secured again I attempted to refit the bumper. I soon realised it was fouling on the intercooler in a few places. This necessitated the use of a hacksaw to cut the bumper in strategic places until it fitted back on. Hacksawing through the nail on my thumb was not part of the plan though

The hub nuts were tightened up and the car dropped back down on the wheels.

Possibly a fraction. The pipes clear speed bumps now and will be higher soon when properly sorted so we'll see.

Thanks mabs, running in is going well. Not planning on a trip to waynes yet unless he can cure my stalling issue, but i've got a few things to try first.

how are you going about running it in matey?

________________________________________

andrew315rawson@live.co.uk
Moonstone phase 7 gti6
My Project thread: http://www.306gti6.com/forum/showthread.php?id=119992&page=1

how did you find the engine build mate?? was it simple enough?

________________________________________

andrew315rawson@live.co.uk
Moonstone phase 7 gti6
My Project thread: http://www.306gti6.com/forum/showthread.php?id=119992&page=1