DaNnY_LaD's IHI'd Cupra ( End Of a Eara 08/11/2009)

[CupraMVR]

Well ....................

Inlet valves all done. what a pain in the ass they are. so small and fiddly,
and then.....

Cams all timed up and torqued down gaskets and seals changed
JOB DONE

 

[DaNnY_LaD]

Truely fab mate

You've done a excellent Job on it too All thats left now is to fit and torque it down then i can get cracking on refitting the bits

Im getting all excited now

 

[DaNnY_LaD]

Big thanks to John and His Wifey for helping me out today while i was at work...

The Heads all done with Headgasket Plus its all nicely torque'd down...Only Problem John has had was getting the large Pulley off for the timing belt as the 4 bolts are on really tight to a extent that they have rounded off...

Shame Really as we could have had the Timing belt kit & alternator belt on all tim'ed up..

I got in from work and got cracking as light was fading fast so only had a few hours...2 at the most...

I got the following fitted:

* Inlet Manifold
* Rocker Cover
* Turbo & Manifold
* Downpipe
* Battery
* Catch Can
* 90% of Vaccum lines
* Spark plugs
* Throttle Bodie Intercooler Pipe work & Dump valve

Its starting to look even more like a engine again

Please excuse the pictures as it was prober cold and there of my phone:

All thats left now is :

* T.i.p
* Timing Belt & Alternator
* fuel Lines
* Charge pipe
* Maf & filter
* Oil & coolant lines
* Tigthen few Manifold Nuts & Downpipe nuts up
* Fill with Oil & coolant

Then I can take it for a drive

 

[s1l3nc3r]

Coming on fast now fella...That manifold looks awesome.

Why not relocate the battery to the boot give you loads of space to get a huge filter in there...?

 

[CupraMVR]

It was hard work glad it didnt rain today.

 

[DaNnY_LaD]

i know...After tonight i was way pissed off..

I started on Finishing the Manifold off bolting it up ect..But i couldnt get it to even sit right...So with light fading fast...

I desided to take the Exhaust off as i was 5mm short on the bolts to tighten up..Anyway 1hr 40mins past and 2x 2'' bolts down i got the Connector off the downpipe which allowed me to tighten the manifold up Nicely...

Ive also got the 3'' tip in place along with maf and filter...Tommorrow with enought time i can get the oil and coolant lines bolted on along with Connecting the downpipe back up(Just Needs tightening)..

Then once thats done ive gotta get to seat and order 4 Crank pulley bolts as they have rounded off as there on soooo tight its unreal,So il have to get a tool sometime in the week to get it off...Looking at it with given time i should have this Running for sunday....Thats the plan anyway....

 

[DaNnY_LaD]

I Desided I needed to spend a few more hours on the car just so i can get it finished...As i can't do anything friday as im going out...

I Ened up getting the full Manifold,Turbo,Oil Retainer & Downpipe all tighten up and nicely in to place...Then i jumped on to the tip,filter and catch can...

Anyway not much todo now

]

the bay needs a good clean and repaint but that can wait tbh...I just need my boost...

All i can think off that need doing is:

* Attach Water & Oil lines to turbo
* Timing Belt & Alternator belt
* Attach some vac lines
* Plug in a few sensors
* Fill with oil & coolant

thats about it irrc...O ive gotta get the 4 crank pulley bolts off 1st lol...

 

[DaNnY_LaD]

Well thats it now...

All thats left todo now is Fit:

* Timing Belt & Alternator belt
* 1x Oil Feed Banjo Bolt
* Tighen 2 x Downpipe bolts

Thats about it...I Fitted all the other bits tonight along with filling her up with Oil & coolant
That then gives me all day saturday to Fit the Timing belt and adjust any teething Problems ...

Il more than likey have the downpipe and Oil Feed Done tomorrow night then i can give it a long deseverd Polish and clean....

Getting all excited now

 

[cupra.al]

dont forget to check the oil level after you started if you havent put extra oil in to allow for the oil filter to fill up.
although im sure you know that.

 

[CupraMVR]

Need to prime the turbo with oil aswell. dont want that spinning without oil in it.

 

[DaNnY_LaD]

Update...

We Got started on it this morning around 11ish when john arrived,So we got cracking with the Timings belt and charge pipe..

We got all the bits done in around a hour or so then the time was to prime and start it...Its started 1st time and it just sounded amazing all my hard work had paid off..
Got it idling for 10mins and there was no leaks or anything loose which i thought great i started to clean up then Boom.,....Something stapped and Locked the engine still only on idle mind..

Anyway Cutting a lock story short the Electrode on my new denso ik22 had came off which then jammed my new supertech valve open then as u now Piston + Valve Bang..
So the all the damage which is there is just 1x Spark Plug,1x exhaust Valve and one Number 4 piston..Nothing else i know its a easy fix and a mina set back but i am lucky to say the least..

It was going extremely well and it was idling and started fine...

Got some Pictures to follow when john gets home...

Tbh i can't beleive it will be making a phone call shortly to the place were i got my denso ik22 from..I know ive heard storys about these denso but didnt expect it to happen to me,...

IM JUST TRYIN TO KEEP POSTIVE AS I WANNA JUST BURN IT...

 

[cupra.al]

thats shocking atleast it hasnt created a massive amount of damage.
i hope that company is going to pay for a new valve piston and give you your money back on the spark plugs.
i take it your going to use a different type of plug now?

 

[DaNnY_LaD]

thats shocking atleast it hasnt created a massive amount of damage.
i hope that company is going to pay for a new valve piston and give you your money back on the spark plugs.
i take it your going to use a different type of plug now?

Yeah mate just sent him a email but will ring them on monday,I heard shocking storys about these plugs from bill but didnt expect it to happen to me...

Ive told john to re fit my old OEM exhaust valves but im glad nothing went in to my IHI turbo or dent the head or bores...
Im looking at the bit now which caused it all and its making me even more pissed off...

When we started it,it wasnt lumpy or sticky nothing the engine just sounded so clean and fresh and it was nice and quite..Until 10mins later

So ive gotta source 1 AYP ibiza Piston....which i suppose isnt that bad but it should off happend...

 

[DaNnY_LaD]

a quick picture of the Bits and u can see the little electrode in the corner which jammed the valve open which then hit the piston..IF u look clolsy it even ripped the collets off...and the stem was stuck in the piston crown..

 

[RobDon]

What a nightmare m8, feel really bad for you.

 

[DaNnY_LaD]

What a nightmare m8, feel really bad for you.

Thanks Rob..

I think i just need to be positive and leave the car alone for a few days and take my mind of it...
I know it runs with no issues like leaks and bits loose..just can't beleive that something like this has caused it....Ive Sourced and bought a new AYP piston for pennys so il wait till thats here then get started irrc

 

[redcupraboy]

Danny feel gutted for you, stick with it though Im sure you will sort it, I think I am going to remove my spark plugs too now as I am currently using the same ones

 

[CupraMVR]

big shame today after the long and awaited start up. it came fired with no probs then stopped

As you can see in pic 1. the end of the spark plug has snapped clean off and bounced about in the cylinder then jamming the valve open and then snapping the valve with ripping its head off. making a big hole in the top of the piston head.

all will be fixed very soon .

 

[CupraMVR]

I was running the same plugs in mine but changed a long time ago cause i heard the focus RS lads were having this problem with there plugs so i took mine out

 

[RobDon]

Stick to good old NGK's ... I do.