WA: Back doors 'Boring'

[Back Door Shenanigans.]

Well.... Its been a long long time between updates so i mayaswell catch up.

The cars currently down at the moment for around 3 months. But its for a good reason. Never thought i'd get there but ms bora is finally getting a new lung. And i cant freakin wait. But more on that a little later.

First ill take a look at my original list

Future Plans:
BBS Lm's
KW V3s? Suspension kit
Turbo
Bora R Front, Back, Sideskirts
Front fog lights (maybe)
Blue Haldex
Respray
Full HID Kit including auto leveling motors
Amps speakers and subs
Fix trip computer (Or install full height trip)
Exhaust
Chip
Cabinaro Intake
ECS Big brake kit v5
Speedtech boser hood extension
Smoked LED tail light (respectable looking ones)
Smoked side markers

So what have i done from that.

BBS Lm's - Done
KW V3s? Suspension kit - V2 fronts and V3 rears
Turbo - In progress
Bora R Front, Back, Sideskirts - Maybe later, Very expensive. Really dislike the current setup
Front fog lights (maybe) - Done ages ago..
Blue Haldex - Orange prefferd. Next on list due to turbo. Should be there once tax comes back.
Respray - hahah yeah not happening
Full HID Kit including auto leveling motors - Not sure probably not
Amps speakers and subs - Done and headunit failed so currently out and for sale
Fix trip computer (Or install full height trip) - No, Hopefully a r32 dash can work
Exhaust - Part of the turbo install. Going to fab my own for the hell of it!
Chip - Part of turbo install
Cabinaro Intake - Done
ECS Big brake kit v5 - Installed a big brembo kit a while back
Speedtech boser hood extension - installed and one of my favourite mods
Smoked LED tail light (respectable looking ones) - LED ones installed that dont look shocking
Smoked side markers - Done

So yeah made a bit of progress which is nice.

And she had a birthday! Just broken in for a turbo....


Now on to the good stuff.

So i finally saved up and got myself sorted. Around i think late september i organized this from a guy in america who had it installed on his 24v.




In the kit is a manifold, Turbo, wastegate, 660cc siemens injectors,fuel pump (which turns out wont work..sigh), ECU with um tune and oil drain and feed lines. Basically everything i needed for the turbo side of things.

I've since sent the ECU and my ECU to united motorsports to swap the tune to my ecu and add an SRI delete which should allow me to keep my immobiliser.

The other thing i sorted out is this beast of a kit.




I loved the idea of an Air/water intercooler specially in australia. A little more complex (well not complex but install difficulty) for some key features. The reservoir has i think a 3gal capacity and a screen for ice. This allows alot of heat to be absorbed and through the use of ice below ambient intake temperatures. It also allows very little intake restriction (less turbo lag) and less complex intake pipework cleaner bay. It comes with a hefty all aluminium water pump and a decent heat exchanger.

The basic plan for this is to install the reservoir and pump into the boot, plumb the lines to the awic which will sit where the battery was (getting moved to boot) which runs to the heat exchanger (in front of radiator) and goes back into the reservoir.

Roughly like this

[Back Door Shenanigans.]

So where am i at the moment.

As stated before the car is down and out at the moment while all this is done. Its quite nice having the time to do this and not need to rush. Mind you this is because i got a second set of wheels (which also started out life broken )


Which is nice and all but i really miss my car and can't wait for its new found power.

Anyway i digress

Currently at the moment the engine bay has the fewest amount of pieces i've ever seen. Basically the core engine is left. I've been very lazy with photos so forgive me ill take more when putting it back together.

The rough starting point


Exhaust mostly out.


SRI delete installed (this was done out of order as i should have been ripping down but i was getting seriously frustrated at the exhaust)


SRI pump removed from front


To get the section between the head and cat off the sub frame needs to be dropped and the steering rack removed. I think this is VW's idea of fun.

Heres the back of the engine once the exhaust is finally off!


Gear box out.


It was ten times easier to remove the gearbox this time. Top reason being no exhaust or most of the parts that get in the way and secondly because i decided to detach the rear drive shaft instead of the box. It hopefully should be a lot easier to put the gearbox back on because of this.

Unfortunately whilst trying to sturdy up the engine it actually fell out of its mounting (my trolley jack failed) and fell onto the floor. Luckily it hasn't damaged anything specially as the harness is still attached. Oh well it should make some things easier i guess.


Still to do. (basic list)
Change clutch and flywheel
Install head spacer
Injectors
Fuel pump
Install all the parts of the AWIC system.
Plumbing.
Solve a dozen problems due to the turbo
Build exhaust
Put everything back together

All "good" fun haha.

I've already had several WTF am i doing and oh **** moments.

[blake_]

Looking great. Going to be a seriously worked bora when its all complete!!
What power gains are you expecting from the turbo setup?

[leighaus]

Awesome project mate. Love people who get their hands dirty for their own pride and joy.

Can't wait to see how this finishes up... Are you worried about the line length from reservoir to the air-water kit?

[Back Door Shenanigans.]

Looking great. Going to be a seriously worked bora when its all complete!!
What power gains are you expecting from the turbo setup?

Thanks, Yeah gonna be awesome. Nothing hopefully to obvious to its turbo aswell.

Well the engine and mods are all good for around 600hp but i wont be going to that. Not really sure thinking of getting an electronic boost controller and setting up a daily around 300 or so, track at 400 and drag at 500. If thats possible.

Awesome project mate. Love people who get their hands dirty for their own pride and joy.

Can't wait to see how this finishes up... Are you worried about the line length from reservoir to the air-water kit?

Haha thanks, I enjoy doing it... sometimes.

Not really. The pump from the reservoir is ridiculous i think its something like 20gal/min. The lines and fittings are what came with the kit so it should be ok. Always chance to change it later on. Most people dont even run reservoirs either.

[work]

Wow, cant wait to see the finished product on the dyno, though the one we used at United a while back seemed to produce lower than expected numbers for the higher powered cars there.

[trickysimon]

Looking good!

[Back Door Shenanigans.]

Haha, We will definitely do another day once shes good to go.

Wow, cant wait to see the finished product on the dyno, though the one we used at United a while back seemed to produce lower than expected numbers for the higher powered cars there.

I got quite annoyed when i looked at your thread. You're beating me

Did you go the r32 route due to the AUE or because the opportunity was there. I've got a bit of an issue getting a tune for the ecu at the moment and not sure which way to go. Would love to do R32 engine but don't have the money.

Looking good!

[Back Door Shenanigans.]

Had an interesting weekend. One of the most oh **** what the hell am i doing moments i've had with the car but all in good fun. Just need to wait until the cars running to see how screwed she is.

Anyway yesterday was all about installing the head gasket spacer and head studs. This involves removing the head and cleaning the two mating surfaces. Whilst i was there as i had to remove the timing chain i did those as well. I'm still missing the top section as its a stupid half cast version but got the lower end done.

Anyway onto the part people look at which is the photos.

So after the rocker cover is off i inspected the cams. My work has got me really paranoid about wear in engines which is helpful and hurting at the same time. But a quick look at my cams show no abrasive wear and the original machine marks still present which is a good sign. Sorry for the bad photo don't have my good camera with me.


Next i removed the upper timing chain. This involves taking the gear off the exhaust cam shaft. A little tip, Don't use a rattle gun unless you don't care about the old timing chains. It will break them (or you could take them off before but shut up).


Then the lower chain off. Did the same here and shattered the slide rail into a million little pieces. Was tossing up weather or not to change the guides but this made the decision quite easy.


Crankshaft timed. Yes its slightly off but i fixed that.


Lower chain and guides installed and mating surface cleaned up.



Before removing the head i prepped the two head gaskets that go between the head spacer. I sprayed some copper gasket spray over them which was a real PITA as they decided to keep sticking to the paper. This will be the issue if i have any but it should be ok as paper is very soft...
Before:

After:


Anyway the head finally came off and the engine gave me quite a shock. Damn she dirty.




Was really quite worried at this stage until i started the cleanup an the stuff came off pretty easily. The crap on the pistons was coming off basically with a spray of the carby cleaner.
Heres the end result. Cylinder liners are dirty but i did clean them. Residue black is the head stained. Its all flat.



Major worry i have at the moment is that all the crap off the head has and will go straight down the oil and coolant galleries. However this should be fine and the stuff is all very small and soft so it shouldn't get caught in the bearings. Note i only used a scraper and scotch brite as using sandpaper can cause a lot of issue if the particles come off into the oil galleries. However a flush of oil and coolant should clean this right up.

Head was kinda in the same condition.
With head gasket


Without head gasket


Cleaned up. I missed a bit on this as it was getting late and its very hard to clean all of the crap off but the majority is done so that should be good.


Head studs installed.


Then removed cause the gasket and spacers wouldn't go back on... sigh




Didn't get any photos of the head back on because... well that stage was late and i was frustrated.. specially as i managed to drop the first washer straight down into the sump....i hope....But i got the rest of the washers and nuts on quite painfully i don't quite like studs. I'm going to have to lift the engine, undo the sump take the washer out and then redo the sump back up as its sitting on the sump at the moment. Then i can torque all the bolts up and wait for the upper timing chain pieces. Thankfully there's still a lot of cleaning and prep work to do before that and the clutch and flywheel. But all in good time

A little update on the tune. I was thinking of going for a piggy back unit as no one does a tune for the coil pack 24v. However stealth racing in the uk has come up with an offer that cant be refused. Basically it involves me flashing my ecu with a tune, data logging and sending the data back to which they will adjust and rinse and repeat. I'm very happy about that as it will take into account any variances in the engine.

[trickysimon]

I got quite annoyed when i looked at your thread. You're beating me

Did you go the r32 route due to the AUE or because the opportunity was there. I've got a bit of an issue getting a tune for the ecu at the moment and not sure which way to go. Would love to do R32 engine but don't have the money.

Sorry, completely missed this!
To be honest, it was mostly because the opportunity was there. That being said, if I was to do it again, I would use the R32 engine regardless of cost. As you know, makes finding parts and tunes etc much easier, not to mention the VVT and monster head ports

Awesome progress!

[trickysimon]

Clear out your inbox btw

[Back Door Shenanigans.]

YAY! got the freaken washer out of the sump without having to take it off.

[RolfGolf]

YAY! got the freaken washer out of the sump without having to take it off.

Small victories make it all worthwhile

[work]

Thanks for showing us the progress pics! Once you've finished on yours can you clean mine out

[Back Door Shenanigans.]

Not along of progress lately, just waiting on timing chain parts coming from germany and a clutch and flywheel. Then i can start putting the engine back together and start building the exhaust.

Just cleaning up some pieces.

Rocker Cover before.

Timing guides before



After



And painted.




Also decided that i would take apart my old head unit to see if i could clean it up and get it working. Wow was there a lot of coke syrup type stuff all underneath the screen. No wonder it was screwing up. No good photos though. Hopefully it works again when i can power it back up. Otherwise its a much cheaper replacement screen at only $180 compared to $850