Can't believe its been over 5 months since I have updated this thread.
Unfortunately I was really busy with work over the summer so project was on hold for a bit.
But managed to get some time to get it all moving and after 5 long hard weeks (or rather weekends!) I have ended up with this:
Sadly I broke my camera so didn't take any pictures until this weekend, but I have done the following:
1. Built up my rebuilt AGU engine - installing head gasket, timing belt etc
2. Fitted the manifolds - the Relentless mani went on fine once I shortened a few studs and modified my heatshield (cut a big chunk out of it!)
3. Fitted ancillaries - wiring etc
4. Fitted new Sachs Organic clutch and Fidanza SMF
5. Removed old engine, gearbox and turbo
6. Fitted new engine, FMIC, pipes etc
Happy to report it fired up first time
Not happy to say had a few issues soon after
![[:@]](/forums/styles/seatcupra/oldforumsmileys/furious.gif "Furious [:@]")
Firstly it was misfiring badly - not sure what cured it as i fiddled with a lot of things but once I did a TB reset it was much better
Second
problem was it sprang a massive oil leak from the timing belt area
Turned out it was the crankshaft seal. It was never changed when rebuilt and so timing belt had to be removed to get to it. Total pain in the ar5e!
The old seal had popped out, so put a new one in - only for that to start leaking after about 30 minutes of running
At this point i was ready to throw in the towel. Took it all apart for the second time and noticed this:
Hard to tell but the inner part of the seal had rolled forward, it should look like this:
This was completely my fault - never installed the seal properly the first time round, so got myself the proper VW seal installation tool for a German website:
Fitted the seal 2nd time round and so far no leaks so look like it is done
Moving away from the engine I decided to sort out the suspension.
I had already bought a full Superpro bush kit for my car, along with some KW V3
coilovers. Since the car was in bits it made sense to fit them at the same time.
Installed the ARB and Rack bush when engine was out. Also polybushed the wishbones:
Then decided i may as well change the bearings, ball joints, ARB drop links too so ended up with lots of shiny new parts:
Left the track rod ends as they were changed a few months back.
Had my alloys refurbished in Gunmetal Grey and got some new Goodyear Eagle F1 Asymmetric 2's tyres as PS3's were past it.
Still got a few more jobs left to do including:
1. Fit rear beam bushes and reinstall my Neuspeed rear ARB
2. Fit WMI tank and finish off wiring it all up
3. Install inline fuel pump (going in engine bay where the carbon canister once lived)
4. Install 550cc injectors
5. Fit brake calipers
6. Put all the interior back in
7. Tidy engine bay a bit more and check for boost leaks before mapping
8. Change VVT tensioner - the current one is knackered as the chain is a bit loose and I'm getting a tapping noise when warm
And loads more too!
Hope it will be ready in about a months time. Then off to mapping she goes
