Turbo Engine Rebuild
- Thread starter scam75
- Start date
scam75
Well-known member
Was up today dropping off my new silicone elbow hose needed to connect the air control line to j-boot. Some more progress. New followers in and cam box is on and belts done. Bell housing is on, exhaust elbow from turbo, most water pipes connected. I think the plan for later today is to connect everything needed to be fired up and fire it up for the first time and do a heat-up and cool down cycle. I think he plans to do this before the exhaust, gearbox, torque tube and some other ancillaries are re-fitted. That will be that for this week all going to plan.
He's then away on holiday most of next week and after that the rest will get done including all the tidy up of plumbing and wiring under the manifold. So I would assume week commencing 4th June would be about right to get it back and start running it in. That is of course barring any disasters! [:-]
Stuart
He's then away on holiday most of next week and after that the rest will get done including all the tidy up of plumbing and wiring under the manifold. So I would assume week commencing 4th June would be about right to get it back and start running it in. That is of course barring any disasters! [:-]
Stuart
scam75
Well-known member
Over a month since last post, my mate got Covid after his holiday and has been playing catch up since so no further progress. Got a text this morning to say car would be running and back with me by this weekend! What can possibly go wrong? 
Anyway, fingers crossed. About 11 months now since it went off the road, in fact super unleaded was about £1.50 a litre then, it hasn't went up has it?
Stuart
Anyway, fingers crossed. About 11 months now since it went off the road, in fact super unleaded was about £1.50 a litre then, it hasn't went up has it?
Stuart
Dan944t
New member
wow that will be a beutifall feeling for you mate ! hope all goes well,… not long now []
blimey i can’t even remember last time i filled up what the rate was? i’m sure it’s coming on for nearly 4 years mines been off the road! miss it so so so much ,.. but with the three young kids it’s almost impossible to find the time to work on it. but i hope to finish my turbo build and replace belts ect in next 3 months ??? we’ll see
very excited for u mate for weekend ,.. one of the best presants you could have to hear it idle again ! ….. i know how it feels …not long now mate!
[]
]blimey i can’t even remember last time i filled up what the rate was? i’m sure it’s coming on for nearly 4 years mines been off the road! miss it so so so much ,.. but with the three young kids it’s almost impossible to find the time to work on it. but i hope to finish my turbo build and replace belts ect in next 3 months ??? we’ll see
very excited for u mate for weekend ,.. one of the best presants you could have to hear it idle again ! ….. i know how it feels …not long now mate!
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scam75
Well-known member
Thanks guys. Not holding my breath, needs MOT'd as well this week although with practically zero miles since last one I don't expect an issue!
I'm on holiday next week so would be perfect to chuck the 10 and 6 year old in the back and rack up some running in miles!
Stuart
I'm on holiday next week so would be perfect to chuck the 10 and 6 year old in the back and rack up some running in miles!
Stuart
scam75
Well-known member
Well what a day I've had in the garage. I'll start with the good news. The car ran for 5 seconds and the rebuilt engine seems all good, well from all of 5 seconds anyway!
Filled it with water and it immediately pissed everywhere. Closer inspection revealed the auxiliary water pump leaking at the seam and then much further inspection revealed the radiator is goosed. I've ordered a Bosch pump noted from a previous Waylander post in an old thread for £50. I've also took a plunge on a £150 aluminium radiator, new, from ebay. Needs must, apparently they are not too bad.
The starter motor also died. Second hand known good one should arrive over the weekend. Also the fuel pump connections seem to have developed a fault, hopefully just a bit of wiring.
The saving grace though was the water leak as it meant we stopped short of connecting up the hard pipes to the intercooler which upon further inspection had managed to fill itself with a litre of water somehow while the car was laid up out in the elements. Glad we never chucked that water down into my new shiny pistons! Intercooler now removed and emptied.
Don't really know what to say about all that. Wait till the new radiator and water pump arrive. And the other starter, and have some more fun!
Stuart
Filled it with water and it immediately pissed everywhere. Closer inspection revealed the auxiliary water pump leaking at the seam and then much further inspection revealed the radiator is goosed. I've ordered a Bosch pump noted from a previous Waylander post in an old thread for £50. I've also took a plunge on a £150 aluminium radiator, new, from ebay. Needs must, apparently they are not too bad.
The starter motor also died. Second hand known good one should arrive over the weekend. Also the fuel pump connections seem to have developed a fault, hopefully just a bit of wiring.
The saving grace though was the water leak as it meant we stopped short of connecting up the hard pipes to the intercooler which upon further inspection had managed to fill itself with a litre of water somehow while the car was laid up out in the elements. Glad we never chucked that water down into my new shiny pistons! Intercooler now removed and emptied.
Don't really know what to say about all that. Wait till the new radiator and water pump arrive. And the other starter, and have some more fun!
Stuart
scam75
Well-known member
So I have a bunch of stuff arriving in the next few days now, radiator today, turbo aux water pump Thu/Fri, a new vacuum check valve (blue/black one under manifold) Fri, 2 x washers for turbo return pipe into sump Fri, starter motor my mate should have collected. Unfortunately he is going on holiday tomorrow and isn't back till 15th Aug, so I would assume we will get it all assembled that week (with a dry intercooler!) and go for another start up. Wiring also needs sorted to fuel pump, seems to have corroded a bit whilst unplugged for months next to fuel filter. I would say what else can possibly go wrong, but I'm fairly confident something else will trip us up! [8|] .
If/when that all goes to plan, refit gearbox and rest of exhaust and that's pretty much it. Surely be done by the end of August........won't it???? That would be a nice round 12 months since she went off the road.
Stuart
If/when that all goes to plan, refit gearbox and rest of exhaust and that's pretty much it. Surely be done by the end of August........won't it???? That would be a nice round 12 months since she went off the road.
Stuart
scam75
Well-known member
Morning all
Well my re-con starter is due for delivery today after it has seemingly hitch-hiked it's way from Germany! This is the final part (yes, for the time being!) before we make another attempt at getting it up and running.
On Monday I will head over to the garage with a new aluminium 3 core radiator (looks really good actually, hope it performs as good as it looks!), re-con 1.7KW Bosch starter, new turbo aux water pump and connector for it (Bosch pump, identical to original except different connector on it for less than 10% of the price of the OEM pump), new blue/black vacuum valve and 2 new washers for turbo oil return pipe to sump. This should (shudder) see things in a leak free environment one hopes!! Assuming the wiring issue to fuel pump is just that (and it seems it is) then we could be looking at another start by the end of the week.
Of course with my mate having been off on holiday, there will likely be a pile of broken Corsa's and Transits at the door just to piss me off but such is life! Surely on the home straight now? No, probably not!
Stuart
Well my re-con starter is due for delivery today after it has seemingly hitch-hiked it's way from Germany! This is the final part (yes, for the time being!) before we make another attempt at getting it up and running.
On Monday I will head over to the garage with a new aluminium 3 core radiator (looks really good actually, hope it performs as good as it looks!), re-con 1.7KW Bosch starter, new turbo aux water pump and connector for it (Bosch pump, identical to original except different connector on it for less than 10% of the price of the OEM pump), new blue/black vacuum valve and 2 new washers for turbo oil return pipe to sump. This should (shudder) see things in a leak free environment one hopes!! Assuming the wiring issue to fuel pump is just that (and it seems it is) then we could be looking at another start by the end of the week.
Of course with my mate having been off on holiday, there will likely be a pile of broken Corsa's and Transits at the door just to piss me off but such is life!
Surely on the home straight now? No, probably not!Stuart
scam75
Well-known member
So after a day of tootaling round Glasgow my starter motor made it safely back to the UPS depot which is departed from in the morning. A class service. I'm thinking, ok Saturday would be ok, nah, rescheduled for Monday, so I thought, ok go pick it up from the depot on Saturday, nah it's closed all weekend. We can now add UPS, Utter Pish Service, to Royal Fail and Parcelfarce.
I should also add that my delivery was scheduled for 9.30-13.30 Wed, then 9.30-13.30 Thu, then 9.30-13.30 Fri, then Fri before end of day, before the guy couldn't be arsed coming to my house yesterday. Also, and work this out cos I can't, in Germany, my parcel was "cleared too late to board the scheduled transport, it will board the next transport" then next morning it was "cleared too late to board scheduled transport, it will board the next transport". Yeah makes perfect sense. So at this point I called UPS GB, they of course said they couldn't help, get the seller to call UPS Germany and they will sort. UPS Germany were less use than UPS GB. Fortunately it boarded some form of transport after a 3 day stop-over in Herne-Boernig. Must have been nice, hope it has some good holiday snaps for me.
Please feel free to denigrate any other "couriers". No wonder Amazon took over the world with some of these ****wits for competition.
Stuart
I should also add that my delivery was scheduled for 9.30-13.30 Wed, then 9.30-13.30 Thu, then 9.30-13.30 Fri, then Fri before end of day, before the guy couldn't be arsed coming to my house yesterday. Also, and work this out cos I can't, in Germany, my parcel was "cleared too late to board the scheduled transport, it will board the next transport" then next morning it was "cleared too late to board scheduled transport, it will board the next transport". Yeah makes perfect sense. So at this point I called UPS GB, they of course said they couldn't help, get the seller to call UPS Germany and they will sort. UPS Germany were less use than UPS GB. Fortunately it boarded some form of transport after a 3 day stop-over in Herne-Boernig. Must have been nice, hope it has some good holiday snaps for me.
Please feel free to denigrate any other "couriers". No wonder Amazon took over the world with some of these ****wits for competition.
Stuart
scam75 said:
Sorry to hear of your problems
I doubt it is all the carriers fault however, the little issue that is Brexit seems to be the main issue.
I've had a couple of parts orders from the US recently and they've arrived within 5 days, however I've had two orders from Europe (Poland and Germany) and they are still "in transit" after a similar amount of time. Both with different carriers, one is Fed Ex and the other is DHL. The kind gent that is sending some hand made parts from Poland said he had to fill in two sheets of A4 for UK customs...
scam75
Well-known member
New bits dropped off, as feared my mate won't be near my car this week. However, he's promised to give me 4 hours a day from Monday next week until it's finished! I would like to think I will be on the road by the end of next week that being the case! Getting close..........
Stuart
Stuart
scam75
Well-known member
Another update.
So the new aluminium radiator is about an inch shorter in height than the old standard one. This in turn drops everything down an inch, meaning the cooling fan cowls don't fit and one of the hoses became an inch too short. Of course, lifting it an inch would have cured this but this was impossible due to the big old oil pipe going to the oil cooler not looking like it fancied going anywhere!
So we were able to connect the top bolts of the fan cowling, albeit after having to make modified bolts that didn't pierce the new radiator (!), a faff but doable. The bottom of the cowling needed a lot of fettling to fit. Suffice to say it's all bolted up solid and in good order now. Also had to nick a small amount of the OS fan blade edges off so they didn't foul on said oil cooler pipe. All good now.
The offending hose, is on the OS side, and is a funny angle (of course), is 23mm inside diameter at rad end and 25mm inside diameter at metal water pipe end, so getting a suitable pipe off the bat would be nigh on impossible. I've sorted this by getting a section of 25mm diameter pipe, cutting a bit off the original pipe, and inserting a flanged metal joining piece in the middle, to give us an extra inch (Oh err missus). This needed cut to the perfect size but we are all good now albeit the little hose now sports 4 hose clips rather than 2! Do need to move the middle clips round as they are too tight to the water pump to rad hose at the mo. Won't be diffucult!
We think this is the last bout of arse ache in what's left to do. Tackle (and slightly modify) the turbo aux water pump later today/tomorrow then we can fill the coolant and check for leaks. See how we go from there! All going well we can rebuild the front end again, refit intercooler, nose panel, air box, boost pipes, j boot, recirc valve etc. etc. Then fit the new starter, then change the washers for the main turbo to sump oil pipe, fix the fuel pump wiring, replace blue/black vacuum valve and then have another go at starting it up!!
If that all goes well then the rest of the exhaust and gearbox can go back on, can refit the PS belt and then, just maybe, we can fit the undertrays and go for an MOT!!
Stuart
So the new aluminium radiator is about an inch shorter in height than the old standard one. This in turn drops everything down an inch, meaning the cooling fan cowls don't fit and one of the hoses became an inch too short. Of course, lifting it an inch would have cured this but this was impossible due to the big old oil pipe going to the oil cooler not looking like it fancied going anywhere!
So we were able to connect the top bolts of the fan cowling, albeit after having to make modified bolts that didn't pierce the new radiator (!), a faff but doable. The bottom of the cowling needed a lot of fettling to fit. Suffice to say it's all bolted up solid and in good order now. Also had to nick a small amount of the OS fan blade edges off so they didn't foul on said oil cooler pipe. All good now.
The offending hose, is on the OS side, and is a funny angle (of course), is 23mm inside diameter at rad end and 25mm inside diameter at metal water pipe end, so getting a suitable pipe off the bat would be nigh on impossible. I've sorted this by getting a section of 25mm diameter pipe, cutting a bit off the original pipe, and inserting a flanged metal joining piece in the middle, to give us an extra inch (Oh err missus). This needed cut to the perfect size but we are all good now albeit the little hose now sports 4 hose clips rather than 2! Do need to move the middle clips round as they are too tight to the water pump to rad hose at the mo. Won't be diffucult!
We think this is the last bout of arse ache in what's left to do. Tackle (and slightly modify) the turbo aux water pump later today/tomorrow then we can fill the coolant and check for leaks. See how we go from there! All going well we can rebuild the front end again, refit intercooler, nose panel, air box, boost pipes, j boot, recirc valve etc. etc. Then fit the new starter, then change the washers for the main turbo to sump oil pipe, fix the fuel pump wiring, replace blue/black vacuum valve and then have another go at starting it up!!
If that all goes well then the rest of the exhaust and gearbox can go back on, can refit the PS belt and then, just maybe, we can fit the undertrays and go for an MOT!!
Stuart
scam75
Well-known member
Ha ha, nearly!
Some more progress. Turbo water pump done and water system is now pressure tested and leak free. Front end all built up (and tidied up) and moved onto replacing starter motor. The 1.7KW one is about an inch longer and the heat shield no longer fits! (It bolts onto the starter ok at terminal end but is an inch short at the bellhousing end) Is there a longer version of the heat shield available? Not a huge drama if not, can do something to secure it. Also the solenoid seems to have been bolted on incorrectly oriented, meaning main wires not reaching/routed incorrect. Possibly a result of the rebuild process. Had a quick chat with Martin (Waylander) on the phone there and he kept me right on some electrical stuff, many thanks Martin! In the end we unbolted the solenoid and re-oriented it as the main wires were not reaching any of the two big terminals. As ever we ran out of time and tomorrow we will have to slightly widen the ring connector on the small terminal to fit over the post, and then we should be ready for another start-up!
Stuart
Some more progress. Turbo water pump done and water system is now pressure tested and leak free. Front end all built up (and tidied up) and moved onto replacing starter motor. The 1.7KW one is about an inch longer and the heat shield no longer fits! (It bolts onto the starter ok at terminal end but is an inch short at the bellhousing end) Is there a longer version of the heat shield available? Not a huge drama if not, can do something to secure it. Also the solenoid seems to have been bolted on incorrectly oriented, meaning main wires not reaching/routed incorrect. Possibly a result of the rebuild process. Had a quick chat with Martin (Waylander) on the phone there and he kept me right on some electrical stuff, many thanks Martin! In the end we unbolted the solenoid and re-oriented it as the main wires were not reaching any of the two big terminals. As ever we ran out of time and tomorrow we will have to slightly widen the ring connector on the small terminal to fit over the post, and then we should be ready for another start-up!
Stuart
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