Post #26
I am glad I am not the only person who destroyed the valve stem seals getting them off.
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| Author | Subject: High Boost Rotrex conversion |
 chris with a pug
Seasoned Pro  Location: Southampton Registered: 16 Feb 2003 Posts: 5,366 Status: Offline |
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 Posted 24th Dec 2008 at 14:21
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buzzbrightyear
Seasoned Pro  Location: hiding all receipts for car Registered: 09 Jul 2008 Posts: 11,894 Status: Offline |
Post #27
im just trying to remember what the woodruff key is for, my old workmate forgot to refit one once and had to take engine back apart to fit it, in some old hgv________________________________________ andrew315rawson@live.co.ukMoonstone phase 7 gti6 My Project thread: http://www.306gti6.com/forum/showthread.php?id=119992&page=1 |
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Posted 24th Dec 2008 at 15:00
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MCH_GTi6
formerly mch  Location: Hayle Registered: 09 Sep 2005 Posts: 2,456 Status: Offline |
Post #28
Looks a good project  Wish I had the spare cash! ________________________________________ Team Moonstone� Ph3 GTI6Team Rallye |
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Posted 24th Dec 2008 at 15:08
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chris with a pug
Seasoned Pro Location: Southampton Registered: 16 Feb 2003 Posts: 5,366 Status: Offline |
Post #29
andy+katie wrote: im just trying to remember what the woodruff key is for, my old workmate forgot to refit one once and had to take engine back apart to fit it, in some old hgv It turns the pullies |
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Posted 24th Dec 2008 at 15:18
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rallyestyle
Seasoned Pro  Location: London Registered: 23 Jul 2003 Posts: 14,990 Status: Offline |
Post #30
Good work Matt Have you rebuilt an engine before? Your step by step approach has made it look quite logical, maybe i should give it a crack afterall  ________________________________________ Just Drive It |
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Posted 24th Dec 2008 at 15:39
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mabgti
NV motors  Location: Bham tunnel @7400rpm Registered: 28 Aug 2003 Posts: 9,127 Status: Offline |
Post #31
Great work dude... glad to see its coming together..NOTE: Be sure to clean off all the paint from the oil cooler exhange mating surface... IF it doesnt seal... you'll have pressure issues ________________________________________ Team Supercharged Gti-6NV Motorsport Automotive Performance Tuning 0121 448 7515 ECU Remapping/ DPF removal VAG/BMW Diag and Option Coding Peugeot Planet ECU coding/transponder programming etc www.nvmotorsport.com Facebook Page Project S6 |
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Posted 24th Dec 2008 at 21:33
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fletch
Track Head  Location: The nearest Shell garage Registered: 12 Jun 2004 Posts: 12,273 Status: Offline |
Post #32
mabgti wrote: Great work dude... glad to see its coming together.. NOTE: Be sure to clean off all the paint from the oil cooler exhange mating surface... IF it doesnt seal... you'll have pressure issues Was cleaned up prior fitting mate |
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Posted 26th Dec 2008 at 00:25
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fletch
Track Head Location: The nearest Shell garage Registered: 12 Jun 2004 Posts: 12,273 Status: Offline |
Post #33
New MLS Gasket: Head is on   All the brackets and sensors werer fitted to the block as well as parts of the wiring loom. The thermostat housing, water and oil pipes were also refitted. Found the oil level sensor had some frayed wiring, so repaired that while it was accessible and dropped it back in. Some new cooler NGKs ready to go into the head, cheap too  Applying the SC kit Sorting the inlet components:   Having test-fitted the Rotrex, Inlet adapter and Inlet Manifold, I used a bit of wire to simulate the throttle cable routing. Given this, I marked up the inlet adapter and compressor housing, ready to fit them together. A punch was used to help retain the inlet on the housing. I then pressed them together.   You can imagine how fast the impellor spins when you see how far it movese in relation to a small turn of the pulley.    Next up was to fit the lower dipstick tube which I had been waiting on, and then the sump.  Had a hand from my assistant cleaning the sump...  The head was torqued up and was now ready to be timed up. Fuel rail fitted - damn you Rich for anodizing it in gold  Suppose it matches the supercharger bracket now...    Grabbed a pulley from Rich and proceeded to time up the engine...  Engine timed up and Exhaust manifold fitted     |
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Posted 26th Dec 2008 at 08:21
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pedro_de_la_cruz
Seasoned Pro  Location: London Registered: 14 Mar 2007 Posts: 2,555 Status: Offline |
Post #34
fletch that is top work gold fuel rail looks funny  ________________________________________ *R.I.P Pete Sims* |
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Posted 26th Dec 2008 at 15:58
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matty_rallye
Senior User  Location: Devizes Registered: 28 Oct 2005 Posts: 966 Status: Offline |
Post #35
Excellent stuff mate, good read that!________________________________________ 2.1 16v 306 Rallye. |
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Posted 26th Dec 2008 at 16:08
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sacko_gti6
Seasoned Pro  Location: Kent Registered: 12 May 2008 Posts: 4,783 Status: Offline |
Post #36
Excellent work so far!Gold fuel rail?  ________________________________________ Build Date - 30 September 1997 - Tuesday's car..is full of pace? |
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Posted 26th Dec 2008 at 19:25
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zac
Seasoned Pro  Location: Leeds city centre Registered: 26 Dec 2005 Posts: 2,627 Status: Offline |
Post #37
Shit hot. Great read! ________________________________________ Hit the limiter in 6th gear at 169mph (GPS - TomTom on the German autobahn). Still pulling like a train too. Cheers- Phase 3 GTi-6 (409hp 'charged weekend toy) - Phase 2.5 Rallye (daily driver) R.I.P Pete Sims |
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Posted 26th Dec 2008 at 19:51
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jib
Seasoned Pro  Location: Doncaster Registered: 21 Feb 2008 Posts: 1,842 Status: Offline |
Post #38
Just goes to show what you can achieve when you have the space, tools, time, finances and know how.Top work mate. Will be keeping a close eye on this one! |
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Posted 27th Dec 2008 at 00:51
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puglover
Banned! Location: Far out there Registered: 08 Jun 2006 Posts: 6,095 Status: Offline |
Post #39
looking good fletch, great write up too |
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Posted 27th Dec 2008 at 00:54
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rich_w
Seasoned Pro  Location: Havant, Hampshire Registered: 29 Jul 2004 Posts: 5,412 Status: Offline |
Post #40
Sorry about the fuel rail Matt  It's been zinc passivated, and is an ideal surface prep for painting, so you could always paint if it's really winding you up ________________________________________ Contact Details:rich@lynxpowerengineering.co.uk 07732 822546 |
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Posted 27th Dec 2008 at 05:07
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fletch
Track Head Location: The nearest Shell garage Registered: 12 Jun 2004 Posts: 12,273 Status: Offline |
Post #41
Had a bit of a rocker cover dilemma and decided on polished covers for now:   Just the PAS assembly to finish...  [Jeremy clarkson mode]Meanwhile.. I now set about putting the interior back into my other GTi-6 to use on the road during the engine swap. Rich came up to sort my ECU out so I could run the car with the new engine fitted. Thanks to his careful skills with a |
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Posted 28th Dec 2008 at 04:23
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fletch
Track Head Location: The nearest Shell garage Registered: 12 Jun 2004 Posts: 12,273 Status: Offline |
Post #42
Engine swapTime to get on with it  One long serving and capable 167bhp engine  Out with the old engine and gearbox...  The "Scooby burger"     My Quaife ATB was fitted to the crown wheel with the help of Sean's compressor. Should help with traction through the bends. Next up was removing the clutch and flywheel and the bolt Sean had kindly rounded off for me   Some grinder and drill action later, flywheel was out and ready to be fitted to the new engine.  |
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Posted 28th Dec 2008 at 04:27
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n3mo
Regular  Location: High Wycombe Registered: 08 Aug 2007 Posts: 177 Status: Offline |
Post #43
awesome read mate looking forward to the next installowen ________________________________________ Deffo Need Better Rubber |
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Posted 28th Dec 2008 at 04:33
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smighall
Smeg-all  Location: b*tching and Whinging Registered: 03 Mar 2005 Posts: 10,012 Status: Offline |
Post #44
Mmmmmm my scooby burger   And those clutch bolts were a f*cking PITA, some muppet must have done them up too tight when they did the clutch ________________________________________  Seat Leon Cupra FR / 306 GTI6 / Breaking 205 GTI6 / Caterham 7 / Mercedes Sprinter 311CDI LWB Sold: Fisher Fury - Laguna DCI Estate - P1 306 XSI - E30 BMW 325i Baur Convertible - Daihatsu Fourtack - Suzuki GSXR600 - 205 Rallye |
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Posted 28th Dec 2008 at 13:10
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mechanical_repairs
Seasoned Pro  Location: leicester Registered: 10 Jan 2005 Posts: 12,122 Status: Offline |
Post #45
Love the burger!Bet that stops hunger for a bit. Going well, engine seems a bit red. Carl ________________________________________ C.G.Cars of Leicester, Peugeot/Citroen/Renault specialist Tel: 01162 624498/07799 405184 WWW.CGCARSLEICESTER.CO.UK36 narborough road south, Leicester LE3 2fn MOT station now open, tests £35 with a free retest. Recovery available with a recovery unit, for those not so local jobs Also offer the loan of a free courtesy car 306 dturbo |
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Posted 28th Dec 2008 at 15:17
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pedro_de_la_cruz
Seasoned Pro Location: London Registered: 14 Mar 2007 Posts: 2,555 Status: Offline |
Post #46
yeah i really want one of them! ________________________________________ *R.I.P Pete Sims* |
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Posted 28th Dec 2008 at 15:23
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cress87
Seasoned Pro  Location: Norwich Registered: 30 Mar 2007 Posts: 11,360 Status: Offline |
Post #47
pedro_de_la_cruz wrote: yeah i really want one of them! +1 That burger looks immense.  ________________________________________ You feed beefburgers to swans. I may have been speeding Mr Policeman but [a] I live for the 306 and [b] did you see that dog? omfg |
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Posted 28th Dec 2008 at 19:32
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mike rallye
Seasoned Pro  Location: mold Registered: 03 Sep 2008 Posts: 1,618 Status: Offline |
Post #48
some good work fletch, will sound awsome when completed |
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Posted 28th Dec 2008 at 23:14
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jib
Seasoned Pro Location: Doncaster Registered: 21 Feb 2008 Posts: 1,842 Status: Offline |
Post #49
Sorry i may be abit late here but you get to choose between a low boost and high boost map at the flick of a switch? Thats some techno shit!Is this the first time this has been done? |
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Posted 29th Dec 2008 at 15:49
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matty_rallye
Senior User Location: Devizes Registered: 28 Oct 2005 Posts: 966 Status: Offline |
Post #50
mechanical_repairs wrote: Love the burger! Bet that stops hunger for a bit. Going well, engine seems a bit red. Carl Christ, id expect it to stop movement for a while aswell!! ________________________________________ 2.1 16v 306 Rallye. |
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Posted 29th Dec 2008 at 16:13
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