Orwell gets boosted (another 1.8t 20v swap) by mk1vDUBtec

10 minute(s) of a 91 minute read

Soooooooooo. I've been busy
I finished my downpipe and exhaust today!
Things are coming together. Fuel lines are hooked up, oil is in, ecu is mounted nicely, and most of the wiring is done.
I also made my own hood pin things to hold the hood down, b/c the stock hood release won't fit in that space anymore.

Still need to:
-finish soldering a few wires
-run vacuum lines to d/v, waste gate, and boost gauge
-add coolant
-install t-body gasket

I anticipate starting it tomorrow
wish me luck!

9-1-2010

 You can see in the pics at the top of the last page that I posted where I mounted the catch can. It's right behind my winshield washer fluid. The AEB's don't have the valve cover hose breather. I only have the block breather hole, so I just ran a line straight from the one block breather to my catch can and then put a breather air filter on the other port in my catch can.
034's catch can picture looks like they just T it in. I want to say just T in the valve cover hose, but don't take my word for it, I'm not familiar with the AMU or AWP's.
I got rid of all my crankcase ventilation crap with the catch can. Puck valve and everything else is gone. I don't see why you would have a problem with just T-ing your valve cover line in... I would probably put one way check valves into the lines to ensure that it doesnt come from one port and go into the other instead of your catch can.
Maybe ask Otti or Vegeta Gti, they seem to really know what they're talking about with 1.8t's in general.

edit: realized this was a new page (for picture reference)

/blabbing

I finished most everything tonight and tried to start her up. wouldnt even crank/click or anything. There's power to the constant starter wire and the ignition switch/starter wire. I cleaned up the terminals and tried again. still nothing. Looked through my bentley some, turned on the headlights, tried to start it and it cranked! (wtf?) then I walk away look through the book some more, come back, keep the headlights OFF this time, and now it cranks again.
I hear the fuel pump prime when i turn the key to the on position.
Then I tried it again and it fired up, and stopped running right away. I don't think I'm getting fuel during cranking. I think the fuel pump is only priming prior to cranking. I'm going to fiddle with some fuel pump wires tomorrow and try connecting it to something else.
Where does everyone else connect their fuel pump ground to??? (since there's no more coil, and the tach needs an adapter to work?)

9-4-2010

Here's some pics of the catch-can setup and my coolant lines:

I'm happy to help.

UPDATESS!!!
The rabbit runs!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!But I haven't driven it yet, because I need to fix a few minor things first.
It smokes off of the manifold/turbo.
My friends tell me that they think it's just the heat wrap though. I put heat wrap around the turbo oil lines and coolant lines. Apparently that stuff smokes until you get it pretty hot to burn the stuff off.

I also have a small oil leak off of the turbo oil return line. I'm going to RTV the connections and hopefully that fixes it.
I also have a small coolant leak off the flange that connects to the coolant return pipe. I think I can fix that too.
I don't think the rad fan is coming on either- I'm going to check the wiring for that and maybe just put it on a toggle switch.
And the last problem is grounding my fuel pump out. I don't want to just ground it to the chasis because then if I get in an accident, the fuel pump wont turn off unless you pull the key out. Any ideas on what to ground it to so that it would turn off?

I refused to spend $300 at the local exhaust shop for a downpipe, so i made my own:

Here's a bay shot:

9-8-2010

So last night sucked.
I took my speedo cable out, and apparently I don't have the clip that holds the gear on, and the gear fell off into the trans. Then I dropped a bolt into the trans. so, I spent all of yesterday after work taking the trans off and then rotating it all around on the pavement until I could see the bolt and gear through the little hole and pull them out. That sucked. coolant leak was fixed though.


Can someone tell me where to ground the fuel pump? I don't want to just ground it to the chasis, because then if I get in an accident, the fuel pump won't turn off unless the key is turned off. I'd just like to make it as safe as possible, and I'm not sure where to ground it on this swap.
Thanks for any help, guys

9-9-2010

I did weld most of my pieces, but in order to take it on and off for maintenance, I have a few clamps. I don't have an exhaust leak, so I'm good.


Update:
coolant leak is fixed.
car runs.
Coolant temp gauge doesnt work, so I'm not too sure what the temp is. I can't tell if my fan is supposed to be turning on or not.
I have an oil leak off the turbo somewhere.
I'm guessing it has to be either oil feed or return line leaking. I took a look up there and it's wet above the return line, so I'm assuming it has to be the feed line that is leaking
This k03-s is causing all types of problems. I wish I had just gone with the standard k03.

9-10-2010

despite my oil leak, I took it out for a small drive up and down the block a few times yesterday and
I am very pleased with it. The turbo sounds great and whistles loud. The exhaust is a little quieter, but it's deep and sounds really good. I would start to get in the higher rpm's in 1st gear and the tires would start to break loose (and they're brand new)

As soon as I get that oil leak figured out, it'll be good to drive about. I'm pretty positive it's leaking from the oil feed line because the AN 90 degree fitting is interfereing with the manifold bolt, and the manifold bolt probably put a hole in it. I have some pictures, but I'll have to wait til tonight or tomorrow to put them up.

9-17-2010

My tach and temp gauge work, and I used no adapters.

I fixed my turbo oil leak! Then i took it out for a drive today. i took it to get gas and was driving all around with it. And then about ~.5 miles from home, I heard a noise, pulled into my driveway, shut it off and popped the hood.

It looks like something blew. I've got oil all over the passenger side of the bay. all over the timing chain and everything. I can't tell what it is. the timing belt shot oil all over the top of the hood too. Any ideas what it is before I start tearing stuff apart?
My money is on the crank seal right now.

I'm not sure, i thought I was getting good flow out to my catch can, how can I tell?

Pictar:

1-12-2011

sorry it took me so long to respond, I forget where the bolt I used came from, but I didn't use any spacers.

Also, I've made some progress. Over Christmas break I took the lower timing cover off and found that the oil is leaking from the intermediate shaft. I replaced the seal and it still leaks really badly. There's shaft also wiggles a decent amount. Seems like the bearings are shot or something. I unbolted the plate that holds it in there and there's like a groove in it from where the metal shaft was wearing against it and there's metal chips. The engine has 130,xxx miles on it.
Anyone have any suggestions for me? Is it some kind of bearing I need to replace? I'm guessing I need a new intermediate shaft and a new plate too right? Anyone heard of this before? Seems weird that it would happen right after I swapped the motor...

Thanks for help