Project codename: Bottomless pit.

[Heat Seeking Missile]

Took the oil cooler to a Serck dealer today, to see what they could do with it. I found a brand new one in the shed but its twice the depth of the original and I dont want to risk smashing it off on the first speed bump I get to.

I'm going to replace the sump gasket as I still have a large leak from underneath there. If that doesn't cure it, its something up towards the bottom pulley leaking. I've no idea what could be by there to leak oil and I dont want to have to start taking the pulley off.

I've been having thoughts about upping the power output of the engine, while I've got the opportunity and its off the road. I've got a Homefry ECU, Milltek cat-back exhaust and a Pipercross panel filter, as well as a set of Samco boost hoses to take more boost if need be. I'd like around 300bhp, which isn't a huge increase, but I want it to be reliable and useable still, I dont like the idea of having to strip any engine internals out but will do if I have to.

I've noticed that my exhaust from the wastegate to the catalyst appears to have been smacked at some point in its life and the bottom of it has been all flattened, surely this cant be helping and would be a good idea to replace.

What are your thoughts?

Mark

[Heat Seeking Missile]

Quick update: Having to get a new oil cooler brought in from Holland as thats is the only place where Chester Radiators could locate one, unfortunately the old one is beyond repair, so my options are rather limited.

I'm still very tempted to replace a few bits and pieces to go for the magic 300bhp. It makes sense while its off the road and on SORN.

I'm thinking RS2 intercooler and turbo and a 3" DP to the cats to replace the flattened section that is there now. Does this sound a good idea?

Mark

[Heat Seeking Missile]

Picked up my brand new, genuine VW/Audi oil cooler yesterday. The old one was way beyond repair and the new one had to be brought in from Holland.

Nice new oil cooler:



On not such a bright note, the flattened, horrible piece of downpipe for the exhaust has completely defeated me today.



It took me near on 3 hours of struggling, slipping, getting covered in oil/*****, just to snap one of the 6 bolts.



Right now, I'm sick to bloody death with the car, I'm getting absolutely nowhere with it, everything I try to take off either breaks, shears or strips, providing I'm off work and the weather is half decent.

I'm bordering on giving up, so it may well be in the "for sale" section soon.

Mark

[S2central.net]

Don't lose heart - I know how frustrating it can be... You line up a few hours out of the day or night thinking you can complete a job - then you lose an hour fighting with one bolt thats either rusted solid or needs seven other things removed to get at it. Sometimes all you can do is take a break from it - time to regroup - think about alternative ways to solve the problem and try again later when you are rested up. That works for me most times - that or lots of swearing and bouncing spanners off the floor

[Heat Seeking Missile]

I just wish I had all the proper gear and the time to do it all. I had to leave before I broke something else, or myself.

I found that to get the other end of this pipe off, the bloody airbox has to come back out yet again. A pig of a job in itself, and one that irritates me no end. I'm very tempted to fit one of them BMC CDA jobbies in there, as its easier to get in and out, as well as leaving me more room for my HID ballasts.

Mr Noisy has been fitted with a new cutting disc today, so i'm going to try and chop off what I can tomorrow, as well as not setting fire to it.

Mark

[s2_bo]

Mark, those exhuast nuts and bolts are a compleat pita! I know how you feel, took me 6 hours to get 6 of them off on my rs2. i ended up cutting them with a small rotary tool as that was all that could get in there.

As far as the sump gasket goes, its not a easy job to change, becasue the sumframe gets in the way of the botls that attach it to the rear crank seal,

Also the sump has two gaskets that sadwich the metal tray that is in the sump. So if you do remove them make sure you get two new ones,

I'd also replace all the bolts and give the things a very good clean, also worth cleaning out the oil pickup pipe while the sump is off.

I have never had the sump off with the engine in situ but i can imagine its a nightmare of a job, you may even have to jack the engine/gear box up to get some better accsess to the rear crank seal bolts.

Good luck and lets hope that you can find the leak with out to much ruble.

If the rear crank seal is leaking you will need to take the engien out or remove the gearbox to change it :s

[S-Express]

Dont lose heart Mark - when I stripped the back end down a couple of months ago - every damn nut and bolt fought me - some sheared, some needed other bits removing so that I could get a bar on them - some needed bigger bolts welding to them to get them off I was totally beat just like you and considered selling as parts. My advice is to leave well alone for a month (its not like you dont have spare cars!) and then go back to it.
I haven't driven my properly since last June, and it will be this June before its finished - but God am I looking forward to it - gives me the physcological push I need.
Have a break mate - have a kitkat......

[S2central.net]

This thread is turning into a therapy session

[Jamo]

Keep at it, if I can you can ( admittedly with help but it's all relative )

[Heat Seeking Missile]

Thanks for the support everyone, its a big help

Bo - That sump gasket sounds a horrendous pig of a job to do, the worst of the oil leak appears to be coming from by the front pulley somewhere but its hard to tell, even after its all been cleaned off. What sort of rotary tool did you use for in the tight spaces for the exhaust bolts? Something along the lines of a Dremel or something similar?

It better be bloody good when its finished!

Mark

[S2central.net]

Sump gasket is a bitch alright... but an extra long allen key for the two bolts tucked up at the rear near the flywheel.

[Alistair E]

Mark

If you don't mind me asking, how much was your oil cooler? Mines looking a bit ropey and I'm just looking ahead.

Alistair

[Heat Seeking Missile]

Erm....it was £177 including VAT (thereabouts). It had to be brought in from Holland but it is a genuine VW/Audi item. ECP wanted £200 for one.

I got it through Chester Radiators (01244 288313) on Deeside Industrial Estate. Very helpful bunch of lads and i'd recommend them.

Mark

[Heat Seeking Missile]

Have had alot going on lately, and alot of things have been getting on top of me, so I'm seriously contemplating selling up now. Its been so difficult to get on with fixing it in between my shifts, fixing other vehicles, keeping the family and missus happy and having decent weather to get out there in.

My idea is to take it to RennTech who can get it working again and back on the road, put some tax and an MoT on it and sell it on.

Not really what I wanted to do, but its getting me down now, its been off the road more than on it

Mark

[Acidburn]

Sorry to hear that mate, but think if tim gets to work on it and gets it running then you will enjoy it before wanting to sell it