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Thread: 1.8t refresh build

  1. #21
    Newbie foster9099's Avatar
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    30th July 2018
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    60.jpg

    I bought the parts a while ago to rebuild the shifter mechanism, mainly because the centering spring was snapped and made it very hard to select 3rd gear. I bought all the bushes and spring required direct from VW which came to a massive £6 in total. I decided to tackle this job after watching a very useful video on Youtube, I can post the link if anyone is interested.

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    The biggest fear it seems is whether this guide bushing that locks into reverse is intact, mine seemed to look pretty good. I don't have any more photos of the process but it is all fairly simple.

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    This is the second time the sub-frame went in, first time was the anti roll bar was the wrong way up and therefore hit the steering arms. I will need to lower the sub-frame slightly again as it seems to be impossible to reattach the steering U joint with the sub-frame all the way up. I also still need to install the rubber boots on the steering rack.

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    Test fitted the brand new washer bottle all the way from china, the old one looked pretty disgusting.

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    The latest delivery is a shiny aluminium radiator designed to fit in place of the original Corrado one, my original one looked in bad condition and probably wasn't helping the much more powerful engine much.

  2. #22
    Newbie foster9099's Avatar
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    30th July 2018
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    Time to make a start on the engine, i'm not going to tear down this engine and rebuild it but i will clean it up and replace some seals and gaskets etc.

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    First is the sump off, there was far too much rtv used previously. I have also removed the pickup and the plastic baffle in this image.

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    There is some bits of metal in the pickup, not really sure what they are from but I cant find any evidence of catastrophe. The pickup and o ring will be replaced with a new genuine part.

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    Side note, I finally got the track rod boots. The picture was taken before I got the tool to crimp the retaining clips on.

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    I did a quick clean of the engine block and laid down the first coat of paint, I wasn't too worried about the finish as I think I will end up with a different engine at some point to completely rebuild.

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    Another side note, managed to get the brake booster/ servo installed. Its a pain to get it lined up while fitting it between the strut tower, a second person inside the car makes the job a little easier.

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    The oil filter housing and oil cooler were cleaned up and painted black and the alternator bracket painted yellow. I began to fit everything back to the engine including the thermostat and knock sensors.

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    This is a mock fitment of the exhaust/ turbo system to help me remember where everything goes. The turbo is a Chinese K04-001 which is supposed to be a bit of a hybrid K03s, however with Chinese quality. This turbo was supposed to be fairly new when I got the car back end of summer last year, by the time I took it off the road the car was smoking quite bad and losing coolant so I suspect the seals in the turbo are gone. I did have a spare K04-001 turbo that came with the car, I had this spare turbo refurbished by a reputable company who fitted new seals, uprated journal bearings and a billet K04 compressor wheel.

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    This was him showing me the difference between the old parts to the new, you can see the oil galleries are much larger in the new parts.

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    This is my refurbished turbo, I will be fitting this once I am confident everything else is in place.

  3. #23
    Enthusiast
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    16th April 2006
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    Think if I had the engine at that stage I'd be tempted to do a set of big end shells at least

  4. #24
    Newbie foster9099's Avatar
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    Quote Originally Posted by Geeba View Post
    Think if I had the engine at that stage I'd be tempted to do a set of big end shells at least
    I was tempted to build this engine but it ran well before apart from the turbo and I want to be driving the car this summer. My plan is to get another engine and rebuild that, most likely with forged rods, while still been able to drive the car.

  5. #25
    Enthusiast 1xshaunx1's Avatar
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    14th December 2010
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    Good stuff, well done matey and a good plan. I can see you achieving it at this rate.
    4th one surely the last

  6. #26
    Newbie foster9099's Avatar
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    Once I had all the plumbing for the turbo sorted out I fitted my refurbished one

    76.jpg

    When I went ahead and compared the 2 turbos side by side, my refurbished turbo has a bigger inlet when is interesting. The turbo on the left (refurbished) was the turbo the previous owner had on the car when it was remapped and when the engine was at its best. They changed the turbo to the one on the right when they had engine failure on the previous engine, they told me that the car was never quite the same afterwards.

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    The engine with all the accessories attached.

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    The clutch and flywheel was in good condition, the clutch actually didn't look that old but it did slip on me a couple of times. I took everything up to CG Motorsport in Leeds to get something that would handle the extra power. They rebuild the clutch plate to a dual friction material, this is organic on one side and paddle on the other. They also refinished the flywheel and pressure plate and gave it all a coat of paint. Sadly I didn't remember to take a photo of the clutch before it all went together.

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    Gearbox on and ready to drop in the car.

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    Back in the car.

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    At this stage all the engine wiring has been connected and the radiator is test fitted with the top cross member.

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    The previous intercooler and piping arrangement was a mess so i'm going to be re-engineering the whole setup. I have some bits of silicone joiners and piping but I will be needing more, I didn't realise how expensive even a simple 90 degree joiner is. Adding all the piping bits I need its easy for it to add up to £50 £60. The image shows the small gap that I have to fit my piping through, there is enough room and it massively simplifies the whole setup compared to what it used to be. The intercooler only just has enough room to fit between the top cross member and the power steering cooler.

  7. #27
    Regular Bauhaus's Avatar
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    5th July 2004
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    South East Essex
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    Thats looking good, coming together quite nicely.

    I was thinking of getting one of those aluminium radiators, how do you rate the build quality of it ?

  8. #28
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    15th October 2008
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    Nice progress, coming together quickly

  9. #29
    Newbie foster9099's Avatar
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    30th July 2018
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    Quote Originally Posted by Bauhaus View Post
    Thats looking good, coming together quite nicely.

    I was thinking of getting one of those aluminium radiators, how do you rate the build quality of it ?
    Just visually it looks really good actually, the pins fit perfectly in the holes on the lower cross member. The top bracket fits into a little slot just like the original. It comes with a plug in the bottom which I removed to screw in the sensor. So actually for the price i'm pretty impressed with it, the real test will be when I get to running the car.

  10. #30
    Newbie foster9099's Avatar
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    30th July 2018
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    You might have noticed the 45 degree bend intercooler pipe that I had originally put on. When I tried to test fit the air filter there was nowhere for the filter to go, I then knew I had 2 options, find a new way of running the intercooler piping or relocate the battery. As it happened a friend has a load of off cut bends of 2.25" stainless steel, I can weld stainless and create a much better fitting pipe run.

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    This is what we came up with, the intercooler piping going down underneath where the air filter will sit.

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    Here is the pipe joining up to the intercooler. Im very pleased with how this turned out. Now i just need to get a couple of fittings, one for the N75 valve and one for the re-circulation valve.

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