Aqua blue pearl VR - p.34 bonnet cable repair

[fla 9]

well the front camshaft was half a link out so I had to remove the side cover and move it back. A bit fiddly, especially as i tried to do it just by taking the cam covers off. Manually turned the engine over once and it was clear. Will do it a few more times as advised before properly turning over (minus the spark plugs and fuel relay) to pressurise the oil circuit.

[Kevin Bacon 5]

The intermediate shaft is like a 3rd sanity check mark. In a normal cam belt engine, the crank turns the cams directly. Just 2 sprockets. In the VR6, there's 3 sprockets (crank > int shaft > cams), so you have to get all 3 timed up correctly or you'll always have a problem with the cams being a tooth out etc.

[Albertcriss 10]

Sweet, love the interior..

[fla 9]

well now the cams are properly timed up, removed relay 167, turned the engine over without spark plug for about 30 secs. Nice oil flow out of the tappets and cams so refitted the cam cover. My son was quite impressed with how the cams turned - but then asked me to press the accelerator down. Until i showed him the loose throttle cable.

I'll be fitting the new fuel rail and cleaned injectors and then its on to OBD2! The plan is to have it running by the end of June hopefully... I seem to remember planning to have it all done by March :(

[sexybourbon 0]

Great work mate glad you got it sorted it's looking good

[fla 9]

thanks Red.

 

New Vredesteins on the TT comps - only fitted one side, the Ronals are on the other side. Need to get some domed centre caps to avoid using spacers on the rear - anyone know whoch ones will fit properly? Comps have been refurbed with a chrome finish rather than polished. Easier to look after.

 

Newly cleaned injectors and resprayed fuel rail also fitted. Used some high temp grease on the o-rings to ensure easy removal next time. Didn't get a pic as it suddenly started chucking it down!

[unomatt 10]

Hi, just having a read through this, your car looks amazing! you say you used loft insulation in the rear quarters, did you glue it in or just stuff it? Is it worth doing?

[fla 9]

Many thanks, although there are far nicer cars on the forum than mine. Its actually been SORN'd for the past 6 months for the little bits and bobs that need doing, so is not as clean as some of the pics make out :(

 

I just stuffed it in - i cant say i thought it made a huge difference though although i had some poor quality tyres at the time which were quite intrusive

As this was done several years ago, I will probably take another approach to noise proofing the rear of the car, using some closed cell foam and mass loaded vinyl sheets or EPDM sheets

[unomatt 10]

If I can get my aqua valver anywhere near as tidy as yours I will be a happy man! Thanks for the advice, hope you get it back on the road soon, mine has been sorned for a month and i'm struggling to resist the urge to tax it again, 6 months must be killing you!

[sexybourbon 0]

Chrome powder coat mate ? Looks good I like the finish of it if that's what it is

[fla 9]

indeed it is, close up you can see its not a proper chrome, polished alloy finish but the ease of maintenance is a big plus factor.

[MarkFoster 0]

Where did you get the chrome PPC done Hasan?

 

M.

[sexybourbon 0]

Yep seen it on some TVR wheels a while ago and was really impressed

[fla 9]

Where did you get the chrome PPC done Hasan?

 

M.

 

They were done at BJV Engineering, http://www.wheelrefurbishing.co.uk. A bit awkward to get to but a very nice area! There was also a small VAG specialist in one of the other units on site too so had a good chat with him, especially as he had a Corrado in front to rebuild.

[fla 9]

got a few hours in today. Managed to remove the engine side portion of the loom. Some very awkward tiewraps under the car for the cables running to the knock and crank sensors, plus the starter solenoid and alternator exciter cable.

Thats now out, and I've fitted the new loom to the newly painted multi-connector bracket.

The main loom I've started removing from the car which is a real mission especially as mine was an auto before and i didn't remove all the redundant loom, plus it has aircon. If VW did the aircon install it really is not tidy with wires crossing over all over the place. This will be a good chance to sort things out properly. And I've managed to locate on leak that's plagued me for years. It is the two aircon pipes that come through the bulkhead below the abs pump. Would never have found them except that I was in the passenget footwell and saw what looked like light shining past the hose! Not really sure how best to seal this, as it wont be that easy to get any silicone in there by hand. We'll see...

 

I've removed three of the four bolts to remove the brake servo, and then i guess the fun will really start!

 

I managed to remove the wiper grommet and fir it to the new loom, just thinking of there is a way to do this with the others too. Basically used some oil to slide the connector out and fit onto the new loom.

 

Also fitted the new wheels on the other side. Ronals will be cleaned and polished and then up for sale.

[zak 0]

Looking good Hasan, glad to see that you're still tinkering away. I like the finish on the wheels, low maintenance sounds good :)

[fla 9]

some slow progress on the weekend - advise from the OBD2 guru, Science, meant i was looking to depin some aircon wiring from the OBD1 loom from the main ecu connector. Slow job, but finally got there. And of course it is too short for the OBD2 loom, so i'll be cutting and extending although i dont think i'll have the right coloured wires.

 

Made use of the old auto loom grommet to run a cable for an amp (another project!) and a solar panel charging panel.

 

As an aside, following advice from others (southerner88 and sean jaymo, iirc), it was much easier to remove the brake master cylinder from the servo and then take the servo out to remove the loom.

 

So once this part of the loom is extended, i will need to fit the aux cooling pump connector and then we start fitting everything back again.

 

Also sealed up the aircon pipe entry points using the same black butyl sealant as used on the door membranes.

Edited July 7, 2014 by fla

[Abdul 0]

Good work as always H, nice to see your dedication hasn't died down!

[fla 9]

thanks guys.

 

Just a few small updates, wiring to obd2 immobiliser corrected (thanks to daves16v and swiftkids notes). Just removed the green connector and joined the black wires to the 6-pin connector. Resoldered the crimped earth cable.

Thanks to Science, the two pins for the aircon high temp switch have been repinnined into the new obd2 multiplug (positions 37 & 39). Very fiddly to get these to fit in again, especially after struggling to remove them from the obd1 connector. The connectors were generally ok, but for absolute neatness i should really have fitted new ones.

[fla 9]

getting there! rotated the injector connectors to fit flat. Fitted the painted inlet manifold which has already picked up some scuffs sadly - too much junk in my garage and not enough space..

 

Generally trying to route the cables properly so hopefully should have most of installed by the next time i tackle it.Looms wrapped in fabric tape and the mishmash of wires for the aircon were unravelled cleaned up and repositioned.

Next time i will re-wrap the other looms where the tape is falling off and generally polish and clean things up.

 

 

 

Struggling with the throttle cable clamp - how should this fit, in fact is the OBD1 able to be fitted to the obd2 throttle body?

Some general engine bay pics with a closeup of the throttle cable clamp.

[science 0]

The throttle cable end just snaps into the space on the Obd2 throttle body, you don't need the clamp/clip.

[fla 9]

Thanks Science.

 

Anyone recognise these two brackets? They're the accelerator stop and the dead pedal bracket. Both had surface rust on them so cleaned them up and sprayed a few coats of hammerite. Will be fitted tomorrow hopefully as i begin work on the interior refit. Engine is pretty much there except the air filter and the main loom connector. I would hope to try and start the car by the weekend - its been SORN'd since October last year :(

 

I've fitted the engine cover and started cleaning/polishing the left side of the bay under the air filter.

 

Crappy engine bay pic, i'll take another tomorrow and post up.

[fla 9]

cleaned and polished the area under the air filter, a thick layer of grease and muck which came off nicely with some white spirit, followed by a good layer of polish. Refitted the plastic surrounds behind the headlight. Stripped and painted the bracket which goes on teh side, not actually sure what its for tbh but haven't fitted it yet.

 

BMC jubilees straps, filter body and silicone polished up and fitted with one of Daves16v's shiny filter straps. The stickers need replacing though. Replaced the screws with stainless.

Need to find a solution to the main round connector issue and swop the lambda connector housing over. The throttle body needs to be sanded and painted and hopefully when the replacement arrives i'll do just that. Then gradually working my way around the bay cleaning and tidying up.

 

I've repolished the slam panel now, but the side channels need a proper clean and polish. Hoping to start it up shortly...

 

Would have preferred red leads but black were the only ones available - at least they're new.

Edited August 15, 2014 by fla

[MarkFoster 0]

.....Would have preferred red leads but black were the only ones available - at least they're new.

 

I think the black ones look fine to be fair Hasan, more, serious looking I guess. Did you get them from VW?

 

M.

[fla 9]

Thanks Mark. They're from gsf, they're the bbt ones.