OEM+ Coupe 16v (1.8t on the way)

[bikerjim]

WOW, what happened there lol. Even reading back through some of that is hard work, sorry but it had to be done!

Anyway back to the build - She runs!!! Wahoo, sooo happy

Sorry the updates have been lacking but I have been so busy. Got back onto it about 3 weeks ago. (Tues 2nd August) Had my appointment at the hospital and doc said I was good do go, so down went the crutches and out came the soldering iron.

After taking Pauls advice, I was a little hesitant at first to remove the whole engine loom due to the snakes nest but when I plucked up the courage it came out no worries. Pulled the whole lot through the engine bay.

I spent the next 2 days methodically working through the wiring, I couldn't of done this without the help and advice of Paul (s2central), so thank you very much. I was left with this -





The bits on the right side of the loom go to the fuse box and the plastic block on the left has 4 connectors on that plug into the engine side of the loom. There are a few other wires left for various ancillaries.

Next job was to put it all back into the fuse box and through this lot -



With that done I turned my attention back to the engine and getting it in:

Flywheel from my original ACE engine (single mass) -



Clutch -





In goes the engine -





By friday 12th I had it in and managed to connect up enough stuff to have a test run. Put some oil in and got my dad on standby with a fire extinguisher lol. Didnt have the water system connected up so just wanted to see if my wiring was going to make it run.
Connected the battery up and the gauges so I could see oil pressure and light. Turned the key, "click", "click", nothing

Then I remembered about the relay I found in position 8 (sorry paul didnt think I had it) on the CEP, I found this while doing the wiring and another relay under the dash that wasn't on any of the wiring diagrams, I had re wired it without to simplify things. Anyway I removed this relay and put a jumper in its place................. Tried again and she fired up straight away Wahoo, the feeling of relief was amazing!!! It ticked over perfect for 30s - 1 min then I switched her off.

[bikerjim]

Went on a short holiday with the misses for the beginning part of this week, then back at it on friday.

Made up some brackets to hold the intercooler in place -







Today I have been tidying up the wiring and doing the piping for the IC. Still got to fab up a down pipe and sort a longer throttle cable out.

Does anyone know of a throttle cable I could use to get a bit of extra length?

Here is how I left her this arvo -

[sam80quattro]

dude what the hell is holding your car up? is that wood? lol builds looking awesome

[caterpillar]

its a spec gearbox jack... i think so..

[bikerjim]

lol, its some kind of crazy Italian ramp my dad has at the garage. It works very well actually. Looks a bit flimsy but once set up its very sturdy, holds freelanders and my dads S6 very well.

[sidrick]

Great progress! Surely not too long until it's on the road now?

[bikerjim]

Great progress! Surely not too long until it's on the road now?

Hopefully not. I start my 3rd year (of uni) placement job on Tues 30th August so I need to have it running and moveable by then. I can see some late nights coming on lol

[bikerjim]

Sorry for the lack of updates on this. Started my placement job on 31st of august and have been without decent internet (phone only) for ages!

Updates to come, here is a taster -

[sidrick]

Is it up and running??

[bikerjim]

It certainly is

Kinda forgot where i got to. Got the engine in and had it running for a short period, was very happy with this, knowing all my wiring worked.

Still had all the piping of the exhaust and intercooler to do along with tidying the engine bay wires and pipes. A quick test fit of the bumper showed i had the intercooler mounted about 8 inches too high so had to modify the brackets and lower it, this actually made it easier to pipe up.

I also went and got some 3" stainless pipe and bends to make up a down pipe. This went surprisingly well considering I had never done it before. I got some stainless wire for my dads mig and gave it a go. I didnt spend as long as I could have done as it will be temporary till I get the T28 in place and it will need modifying.

Anyway, here are some pics.









Once I had got it up and running It was time to get it MOT'd. On first running it I thought I had water system problems. It was getting really hot on the gauge (115C +) but the thermostat wasn't opening. Spent ages searching online for a possible cause and after reading some posts on a VW forum it turned out that the coolant temp sensor was making the gauge read wrong.

I checked this theory out with a snapon solus machine and watched the coolant temp the ECU was seeing, and true enough it was much lower than the gauge was showing, I had been shutting it off before the thermostat opened

I swapped the CTS for a black one with a yellow band and everything was spot on. Put it through an MOT and took it for its first running in drive.

It was ok but felt a bit odd, it would cut out now and again and ran a bit lumpy. Turned out the airflow meter was goosed!

Did about 50 miles on cheep as chips mineral oil, changed the oil and filter and went for Millers competition running in oil. The car was running better than I ever could of hoped for. I couldn't believe after all that, it just worked!

[bikerjim]

After about 900 miles of running in I changed the oil and filter again for the correct oil for the car. Then it was time for a long test lol. I took the car all the way to the isle of mull for the Mull Rally. It did everything I could of hoped for. It pulls really strong and is alot more effortless than the revvy 16v lump. The new brakes feel really good and are much more positive than before.

Here are some more pics:





















I still have plenty to do to the car but my time is now alot more limited with my placement job and facilities are not so available.

I have also fitted:

ABY airbox for a nice OEM look
Wired in a FUNK switch for the fans
Fitted one of rustys boost guages in place of the volt meter, and relocated a digital volt meter to the ash tray.

Jobs still to do:

- Make splash guards/cooling ducts for front brakes
- paint (black) and fit grills into bumper
- fit lower profile brake fluid reservoir and fit strut brace
- rebuild and fit T28 turbo + all associated bits + get mapped
- + etc etc etc lol

[TimE-J]

Looks great, well done for getting it up and running!

[andy10v]

Looking good mate, congrats on it all coming together.

Good job on the diy downpipe as well.

[sidrick]

Looks superb, great work

Did you just go for the A4 rear brakes? Did the disc and bearing setup fit fine with the original stub-axle and marry up to your original calipers and carriers? It looked like that should be the case from the part number research I did.

[BLAMM0]

looking nice, thats my "old idea" about a swap to this motor from an old 4 cylinder, 85kw unit