IH786's LCR BBT K04 - Full spec list on page 1!! / Colour change - Finished?

[IH786]

And just one final post!

I have also trial fitted my Walbro fuel pump, installing all the wiring. Hid it quite well, around the scuttle panel area. The pump will be mounted where the charcoal canister currently sits.

Also have fitted my WMI, have no pics of that (or the fuel pump install).

Still deciding the final location of the tank in the boot.

Its all coming together nicely, but still tons of work to do!

 

[seatcupramad23]

you beading the pipes ?

 

[IH786]

you beading the pipes ?

Yep getting them done by a guy I know over in Selly Oak, dropping them off next week

 

[IH786]

Also have bought this too:

Mocal 16 row oil cooler

Along with this:

I went with the 80 degree thermostat option. All off eBay. Cost £150, which I thought was fairly reasonable.

Also have got the IE coil pack adaptors and TFSI coil packs.

So the plan is to get a complete engine built up with all the mainfold, turbo, wiring, ancilliaries etc ready to be swapped straight for my old engine.

Got it planned out in my head, hope it all goes smoothly..........

 

[seatcupramad23]

Loving the progress my car progress been halted due the garage having my car trying to fit coiloveres relentless manifold and powerflex wishbone bushes.

 

[IH786]

Loving the progress my car progress been halted due the garage having my car trying to fit coiloveres relentless manifold and powerflex wishbone bushes.

Thanks mate

Thats a lot of work being done to your car. What coilovers are you fitting?

The manifold is meant to be a real pain to fit, glad my engine is out when i'm doing mine

 

[seatcupramad23]

Kw v1s, manifold is a pain

 

[IH786]

Update time -

I have finally managed to install my Toyo 600x300x76MM FMIC and Mocal 16 Row Oil Cooler

Went with 76mm pipework, with a custom MAP pipe, and also had a WMI bung welded in too

Have gone into lots of detail in this thread:

http://www.seatcupra.net/forums/showthread.php?t=353162

So just some pics here:

Along with this I have also installed my Nomad dual pillar pod and Stack Boost and Oil Temp guages. Not taken proper pics of this yet, but it was not as straightforward as planned!

As ever, any comments are welcomed (well positive ones!)

 

[Chambers_CUPRA]

Is the intercooler not a bit restricted by the crash bar?

Only ask as I've got to fit one to my Ibiza but was worried about blocking the cooler?

 

[Dan1720v]

Its more about surface area. Think how much bumper is in the way too...

 

[seatcupramad23]

you don't hang around do you , is that the new engine in still running the old one in yours

 

[IH786]

Is the intercooler not a bit restricted by the crash bar?

Only ask as I've got to fit one to my Ibiza but was worried about blocking the cooler?

As Dan said, its about surface area. Although I am planning on running a smaller plate and increasing the honeycomb area on the grille to allow a bit more airflow

you don't hang around do you , is that the new engine in still running the old one in yours

Honestly mate feel like I am doing everything too slowly! The engine is my original 124.5k and still running strong

Next stage is to get the engine built and fitted.

In the meantime there are a few small jobs to do, like decide on the final the location for my WMI tank, plumb in the the gauges, fit my coilovers, get my holy boot welded up......

The list seems endless

 

[Ronin225]

Looking good, i think i'll be going 13 row cooler after seeing the size of the 16 row

 

[IH786]

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

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

 

[IH786]

Few more pics of the engine bay. Wasn't too sure about the colour of the SEM, charge pipe and cam cover (its the same as my calipers) but it is starting to grow on me:

Also need to fit these bad boys:

My method of removing rear axle bushes - lots of fun!!

 

[EL]

Blimey you really have been busy haven't you. Great to hear its coming together. Bet you can't wait until it is done and mapped. Finally be able to enjoy it properly

What oil catch can is that btw?

 

[Chambers_CUPRA]

Looking good mucka

When you fitted the oil cooler did you have to get a shorter thread union (bit that goes through the oem cooler and the oil filter screw onto)

 

[IH786]

Blimey you really have been busy haven't you. Great to hear its coming together. Bet you can't wait until it is done and mapped. Finally be able to enjoy it properly

What oil catch can is that btw?

Thanks Its been hard work - there it was not a simple engine swap there were lots of extra little jobs.

A good example would be fitting the SEM manifold - it does not have mounting points for the OEM EGT sensor like the LCR mani does - so had to make a bracket to mount it by the chassis leg, and shorten the wiring.

On top of that had to also lengthen the wiring for the TB, Knock Sensor and Cam Sensor.

The catch can was bought off RobDon (along with the SEM, TB, Fuel Pump and Fluidampr Pulley) - not sure what brand it is, think it might be custom.

Looking good mucka

When you fitted the oil cooler did you have to get a shorter thread union (bit that goes through the oem cooler and the oil filter screw onto)

Yep that to use a shorter thread union thing - P/N: 059 115 721

 

[seatcupramad23]

glad to see you sorted it mate

 

[Mo Arif]

I'm certain i've seen those engine mounts before.... good job mate