Transformation of pleasant family car to politically incorrect monster

[gedu]

Right. ECU is going by post to get tested/checked/repaired, just to be sure. I still have no RPM signal while cranking. Sold both "china" rod sets (yes, even the one inside the engine currently). Decided to to do full engine stripdown (yes, again), block to machine shop to be drilled to 81,5mm, new pistons, Pauter (or Carillo or PO Metal, not decided yet) rods, OEM bearings (not 034 coated ones). Also sold Wagner intake, as one rod set went to a RS2 owner, and I showed him that intake, and he decided to buy it

In summary, 1st evolution version of engine never even started

[gedu]

Yeah... well, I already have motor detached from gearbox, only need to lift it out

[90quattro]

Right, today got around to test if flywheel "home" pin is in it's position... You guessed it, nope, it isn't there. Engine is coming out again, easier to lift it out than drop gearbox with no lift.

If you take out the starter then you get access to the flywheel. It should be enough room to replace the pin.

Tom

[gedu]

Right, today got around to test if flywheel "home" pin is in it's position... You guessed it, nope, it isn't there. Engine is coming out again, easier to lift it out than drop gearbox with no lift.

[gedu]

Right, Now I have my hands on new cam pulley (ordered from finnish manufacturer, and it's got Dahlback printings on it 149€ delivered vs dahlbacks price). Also have new hall sensor, so will start to assemble today.

[Bram]

ok, good that you checked it at least!

[gedu]

Got new hall sensor. When removing cam pulley key stayed on camshaft slot... 2nd pulley broken

And no wonder Hall wasn't giving any signal... the wasn't any sensor, only a bit of housing left

[gedu]

Hrmm, no editing last post then.

Measured triggers tonight with 'scope and found that Hall sensor is shorted. This might be the reason for no start, as it could mask out crank pin.

[gedu]

Been a bit lazy, and last 3 weeks have went by because some quite resistant Streptococcus pneumoniae bacteria have decided to live in my right elbows bursa. Good thing is, it hasn't spread from there, but these medications are no fun :S

VEMS should be now fixed though, but haven't had the motivation nor possibility to work on car, so don't know if all is well.

[gedu]

ARgh, still not running. No RPM signal in VEMS, now chasing that. Most likely I have broken something from ECU as there was some grounding problems. Need to measure some more, trigger signals seem to be kind of weird...

[gedu]

Today I found at last the electrical gremlin that has been keeping on the edge for last 2 weeks. Found a melted wire that has quite astronomical resistance when measured with dvm. Got around 50mV from other ends connector when measuring against earth, and that wire should be supplying 12V to various parts of car.

Funny thing is, I haven't burned it myself, so some earlier owner perhaps has short circuited it at some time, and it stopped working now, after who knows how long.

Oh, and while debugging this problem, I also found some old relay from conlog, masquerading air-con relay

[gedu]

Right. Head back on, manifolds in place, turbo hoses connected, dp bolted on, lambda on, egt sensor mounted. Need to mount hall sensor connector bracket, tighten timing belt and check water return hose mounting, then I'm ready to start trying to get motor running. Chargecooler needs expansion tank, have to figure out where to mount it, most likely somewhere near firewall, where there are quite much places to hang it on. Oh, and still need to sort hydraulics cooler.

[gedu]

seems like I got away with my mistakes, no marks on valves nor pistons.

Need to put head back on (removed head in 2,5 hours ) and change rpm sensor, as don't have rpm input to VEMS.

[Bram]

Timing belt snapped? I don't hope so for you! Keep us updated and pray for the best

[gedu]

No problems with clearances on hotside. Compressor housing is more tight in it's place, filterhousing heatshield needed some hammering to clear coldside.

I'll try to take pictures about it, have to lift head of. Most propably I have bent all my valves