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Author Subject: High Boost Rotrex conversion
chris with a pug

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Location: Southampton

Registered: 16 Feb 2003

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Post #26
I am glad I am not the only person who destroyed the valve stem seals getting them off.
Posted 24th Dec 2008 at 14:21
buzzbrightyear

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Location: hiding all receipts for car

Registered: 09 Jul 2008

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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.uk
Moonstone phase 7 gti6
My Project thread: http://www.306gti6.com/forum/showthread.php?id=119992&page=1
Posted 24th Dec 2008 at 15:00
MCH_GTi6

formerly mch

Location: Hayle

Registered: 09 Sep 2005

Posts: 2,456

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Post #28
Looks a good project Thumbs up

Wish I had the spare cash!

________________________________________

Team Moonstone´┐Ż Ph3 GTI6
Team Rallye
Posted 24th Dec 2008 at 15:08
chris with a pug

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Location: Southampton

Registered: 16 Feb 2003

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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
Posted 24th Dec 2008 at 15:18
rallyestyle

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Location: London

Registered: 23 Jul 2003

Posts: 14,989

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Post #30
Good work Matt Thumbs up

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 Yes

________________________________________

Just Drive It
Posted 24th Dec 2008 at 15:39
mabgti

NV motors

Location: Bham tunnel @7400rpm

Registered: 28 Aug 2003

Posts: 9,127

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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 issuesYes

________________________________________

Team Supercharged Gti-6

NV 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
Posted 24th Dec 2008 at 21:33
fletch

Track Head

Location: The nearest Shell garage

Registered: 12 Jun 2004

Posts: 12,273

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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 issuesYes


Was cleaned up prior fitting mate Thumbs up
Posted 26th Dec 2008 at 00:25
fletch

Track Head

Location: The nearest Shell garage

Registered: 12 Jun 2004

Posts: 12,273

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Post #33
New MLS Gasket:



Head is on Smile



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 Smile



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. Cool




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 Roll eyes 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





Posted 26th Dec 2008 at 08:21
pedro_de_la_cruz

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Post #34
fletch that is top work Thumbs up

gold fuel rail looks funny LOL

________________________________________

*R.I.P Pete Sims*
Posted 26th Dec 2008 at 15:58
matty_rallye

Senior User

Location: Devizes

Registered: 28 Oct 2005

Posts: 966

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Post #35
Excellent stuff mate, good read that!

________________________________________

2.1 16v 306 Rallye.
Posted 26th Dec 2008 at 16:08
sacko_gti6

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Location: Kent

Registered: 12 May 2008

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Post #36
Excellent work so far!

Gold fuel rail? Blink

________________________________________

Build Date - 30 September 1997 - Tuesday's car..is full of pace? Wink

Posted 26th Dec 2008 at 19:25
zac

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Location: Leeds city centre

Registered: 26 Dec 2005

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Post #37
Shit hot. Great read! Cool

________________________________________

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
Posted 26th Dec 2008 at 19:51
jib

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Location: Doncaster

Registered: 21 Feb 2008

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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!
Posted 27th Dec 2008 at 00:51
puglover Banned!

Location: Far out there

Registered: 08 Jun 2006

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Post #39
looking good fletch, great write up too Thumbs up
Posted 27th Dec 2008 at 00:54
rich_w

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Location: Havant, Hampshire

Registered: 29 Jul 2004

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Post #40
Sorry about the fuel rail Matt Laugh

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

Laugh

________________________________________

Contact Details:

rich@lynxpowerengineering.co.uk
07732 822546

Posted 27th Dec 2008 at 05:07
fletch

Track Head

Location: The nearest Shell garage

Registered: 12 Jun 2004

Posts: 12,273

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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
Posted 28th Dec 2008 at 04:23
fletch

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Post #42
Engine swap

Time to get on with it Devil

One long serving and capable 167bhp engine Smile



Out with the old engine and gearbox...



The "Scooby burger" Crazy





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

Whistle Roll eyes



Some grinder and drill action later, flywheel was out and ready to be fitted to the new engine.

Posted 28th Dec 2008 at 04:27
n3mo

Regular

Location: High Wycombe

Registered: 08 Aug 2007

Posts: 177

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Post #43
awesome read mate looking forward to the next install


owen

________________________________________

Deffo Need Better Rubber
Posted 28th Dec 2008 at 04:33
smighall

Smeg-all

Location: b*tching and Whinging

Registered: 03 Mar 2005

Posts: 10,012

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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 Whistle

________________________________________

Meh

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
Posted 28th Dec 2008 at 13:10
mechanical_repairs

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Location: leicester

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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.UK
36 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
Posted 28th Dec 2008 at 15:17
pedro_de_la_cruz

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Location: London

Registered: 14 Mar 2007

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Post #46
yeah i really want one of them! LOL

________________________________________

*R.I.P Pete Sims*
Posted 28th Dec 2008 at 15:23
cress87

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Location: Norwich

Registered: 30 Mar 2007

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Post #47
pedro_de_la_cruz wrote:
yeah i really want one of them! LOL



+1 That burger looks immense. Shifty

________________________________________

Ph3 China blue GTi-6 330Ci///M Sport & NC23 CBR400RR Cool

You feed beefburgers to swans. Yes

I may have been speeding Mr Policeman but [a] I live for the 306 and [b] did you see that dog? omfg
Posted 28th Dec 2008 at 19:32
mike rallye

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Post #48
some good work fletch, will sound awsome when completed
Posted 28th Dec 2008 at 23:14
jib

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Registered: 21 Feb 2008

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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?
Posted 29th Dec 2008 at 15:49
matty_rallye

Senior User

Location: Devizes

Registered: 28 Oct 2005

Posts: 966

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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.
Posted 29th Dec 2008 at 16:13

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