Jogi's New Project

[andy10v]

What size is the cobra head you are after?

I have one waiting to go on my S2, but that will not happen in the next few weeks.

[jogi730]

Ok, progress is painfully slow I'm afraid, but engine has finally been fitted - more updates to follow.



However, now faced with another big problem with the 6 speed conversion. The clutch is not working so car will not move,
It seems there is not enough travel for the clutch to disengage. The clutch does not work until bearly on the floor. The system has been checked over and over for air and that is ruled out.
Using the old typ85 Master cylinder and 6 speed slave as has been done before but there just doesn't seem to be enough fluid to work the clutch. Could the 01E CYT coded diesel gearbox be that different from the CGR?
Has anyone encountered this problem before? Any suggestion please?
Thanks in advance.

[Christophski]

Glad there has been progress Chris but shame about the clutch. Im not clued up on conversion things so im afraid I cannot help.... Keep with it though and good luck

[twoqu]

Chris,

Might be an idea to list what components you used on the clutch side including the flywheel. Might be a mismatch, particularly with the pressure plate.
Although it seems there was an issue with the clutch plate initially!

[Pirvu Eugen]

Hy Chris! Are you sure that the master cylinder piston is not stuck?
Using an sucking device for removing air from the system will not show this.
I had mine in the same situation after sitting in garage for long time with the clutch pedal down.
Hope this helps!
Regards!

[G60Rallye]

Try using the longest rod you can get in the slave, so it pushes as far as possible.

[stocious]

is there a spacer between block and box ?

[jogi730]

Thanks for replies guys. Most helpful.
No spacer between engine and block.
Cheers
Chris

[jogi730]

As promised further update. Progress has been very slow for lots of reasons especially various problems – the clutch not resolved as yet, but there is light at the end of the tunnel now.
The new clutch plate was finally fitted.


The engine was now literally shoehorned back into the engine bay. The new inlet and exhaust manifolds had moved things sufficiently to make the fit even tighter than before.

But a lot of effort has gone into the aesthetics and I like it myself.

[jogi730]

However, this has caused several new problems which had to be overcome.
The downpipe had to be altered and has been worked to be further away from the Brake servo with the wastegate pipe grafted in.





The wastegate itself was then installed and attached to the turbo.





[IMG]http://i271.photobucket.com/albums/jj135/jogi730/DSCF2273.jpg[/IMG

[jogi730]

The next problem was the boost and coolant pipes with everything being so tight at the front. So here we have Spaghetti Junction

[jogi730]

A new rear silencer was needed and the rest of the exhaust was also reworked for a better fit

[jogi730]

Despite trying to order the tight bend to overcome a previous problem of getting pipework to the throttle body, the only way around it was to slightly shorten the intake manifold and rework the throttle boddy itself

[jogi730]

Unfortunately, due to the car being off the road for over 4 years, a few additional jobs had surfaced to get the car through the MOT with dreaded corrosion setting in despite the car being garaged throughout.

[jogi730]

So this is where I am at with my project. Hoping not too many other things will hold this up now.