All Things Mk5 > Members Rides
LC5F's Graphite Blue GTI - Pilgrimage to Caffeine & Machine
LC5F:
--- Quote from: G-olf on August 24, 2021, 07:05:47 am ---Looking good, bet you can't wait to be up and running again :smiley:
Sump and pick up pipe clean is also on my list. Had much sealant squeezed out on the inside when you took it apart?
Did the pick up gauze clean up fairly easy?
At least it will have chance to set nicely as you don't have to run the engine straight after.
--- End quote ---
Yes - I've had itchy feet for a few weeks now - really intrigued how it will drive with all these many improvements.
Pick up is really easy to clean - I can't understand why some people buying a new one, that is unless there has been some failure they are fixing - I understand they are over £40!
It is stainless, I just dunked it in the £9 Screw-fix no-nonsense de-greaser and left it there for 30 minutes, then picked it up scooping fluid and allowing it to drain through the mesh few times and then back in to soak for another 30. Then took it out rubbed the mesh with a paint brush and then reverse rinse under cold tap and I could see the flow improve with each rinse.
How I messed up the sealant - On the front of the block there are 2 brackets that hang down at the side of the sump - one carries the secondary coolant pump - if possible I would recommend unbolting them and pulling them away from the sump - it would have made cleaning the block easier + easier to fit the sump.
And I should have practiced placing the sump into position a few times without sealant...
In other news-
The Turbo shaft and impellers should be back from balancing with me by Friday. Shaft was inspected when they received - the shaft and the oil seal were scored... new shaft required, so more monies!
The head stud tool is on its way (Yay!), but it's being delivered by Hermes (Boo!)
- So I will be pleasantly surprised if it arrives on time.
Mekaniko:
:congrats: :congrats: :congrats: :congrats: nice work in progess!
Reagrding the pick-up, on a workshop is cheaper for them to just change as it if they need to charge the labour of cleaning the part it will be the same same price maybe...but I take note for mine!
LC5F:
Well, I'm pleasantly surprised - hermes showed with the tool this afternoon.
This evening I installed the head, cam sprocket, vacuum pump, coolant flange and injectors - only issue was lining up the locating studs took a few goes, but everything else was good and the result is:
In the head gasket kit I have a 3 mystery O-rings - I can only assume these are for the vacuum pump??
The remaining work will be split into smaller chunks of:
Timing belt, covers, engine mount & drive belt
Re-install intake
Rebuild turbo and re-install
--- Quote from: Mekaniko on August 25, 2021, 06:12:05 pm ---Reagrding the pick-up, on a workshop is cheaper for them to just change as it if they need to charge the labour of cleaning the part it will be the same same price maybe...but I take note for mine!
--- End quote ---
Thanks - I would say my actual physical contact with the pickup was less than 5 minutes - an hour just soaking by itself.
LC5F:
Thursday - added the timing belt and engine mount
Friday - installed the intake manifold, the rather dramatically named satan bolt was easy to do up with the dip stick tube removed:
lost a 1/4 drive T30 bit out of my set while installing the throttle - hopefully it will extract itself and get caught by the undertray.
Balanced turbo turbines were delivered - just need to line up the markings:
Saturday - turbo rebuild, kept finding it jamming once the nut bolted up, worked out it the issue was I was using the original oil deflector and the diameter was different, once the new deflector shape was adjusted it all went together.
After going to so much trouble it seemed silly putting some 22 month old spark plugs in + I needed G13... so another trip to TPS, surprised the VW have moved to pre-mix - more packaging / more volume / more weight / more transport cost / more cost to end user - bit of a non-environmental richard head move VW.
Bit surprised to see NGK's have been dropped for Bosch:
Got everything installed, filled up oil and coolant and spun the engine over with coil packs disconnected.
Connected up the coil packs and went for first fire - after a long clank it started to splutter and fired up - complete raket - huge manifold leak, I had not seated the turbo correctly! - I shut it off after a couple of minutes.
Sunday - Did a check for leaks in all the joints, pleased to say everything was dry.
Re-seated the turbo required all the manifold bolts loosened - for anyone following me, the key is undo the driveshaft at the box and then gives a lot more room.
All back together again, fired up and it was quiet, no strange noises apart from a ticking from the injectors and chatter from the drive belt tensioner - ran it up to 90 and everything was good.
Never heard the secondary coolant pump running after shut down, inspecting I found a pin-hole leak in the coolant hose next to the pump
Box of leftover bolts - the big 18mm ones are from the turbo heat shield - that I really can't be arsed to fit! I have no idea where the other T30 bolt comes from:
How does it drive - well I had done so much to it just before it ate the drive belt, it does feel very strange.
But it has lost its urgency, I suspect I may be a tooth out in timing - at this stage after 5 weeks I am just relieved it's all back together
pudding:
Wow, what an epic transformation and a complete battle of the crusties. Epic work :notworthy:
That T30 bolt kind of looks like the lower vacuum pump to me, just above the inline stat, which also holds a wiring harness bracket in place.
Thanks for confirming the Rocco hubs cause rubbage. I'm not going to bother fitting mine now :grin:
It should be proper peppy with head and turbo refreshes. A tooth out on the timing ought to be fairly evident in VCDS looking at measuring blocks 91-93. Cam phase position should be around 0-4KW and the actual and requested phasing angles should mirror each other quickly. Maybe it needs more time to get oil everywhere. When I replaced my VVT phaser and chain etc, it did take a while of idling and revving/ECU adapting for the numbers to all come good.
Keep at it, you've done some sterling work there :drinking:
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