AJmk2 2 Posted August 23, 2013 Report Share Posted August 23, 2013 Hi all, thought id upload my latest project....I recently went and purchased a fairly complete mk3 golf with 4 motion swap, some of you may remember it from on here On start up the engine was quiet but once warm you could start to here a slight clonking. This I thought was the chains as it sounded almost identical to my old engine when the chains needed doing.After 15 mins of driving the car home I decided I didnt want to risk any damage so had the car recovered to a friends garage and thats when the fun began.To take the cover off the engine the whole front end needs to be removed. After taking the cover finally off it was noticed that there was very minimal wear on the chains/guides so it was decided time to drain the oil and check the sump. It then became clear that a bearing had decided to vacate the block [8(] I tried to find a crank to replace the one in the block but after searching I could not find one.Instead I picked up a complete engine from a "low" 70K Ford Galaxy.So the strip down began. Link to post Share on other sites
AJmk2 2 Posted August 23, 2013 Author Report Share Posted August 23, 2013 Bottom mount turbos I have discovered are things of the devil.Trying to undo the manifold bolts/wastegate is a pain, V-Band/top mount is the way to go.With the engine out at least it gave me a chance to get to know the setup and inspect everything. Engine is running a Helix SMF and Clutch/Pressure plate.This is the second helix setup I have used on VRT, both have quite heavy pedals but this one is using an organic type disc which is much more easier to control compared to the 4 puk on my old setup.The head off my new galaxy engine could not be used as it had VVT however the blocks are identical. The new block was stripped down and all tensioners,chains,guides removed to be replaced by new parts.When looking at the turbo it was found that it would barely spin but didnt have any play at all. At this point I was very unhappy as it seemed a long list of things were wrong with the car. Soaking the bearing housing for a few days resulted in it spinning a lot easier. Must have had coke build up. On closer inspection it was also found there was a small hairline crack in the exhaust manifold so I had to call on my friend for a bit of welding. Link to post Share on other sites
AJmk2 2 Posted August 23, 2013 Author Report Share Posted August 23, 2013 And back in it goes!First start was great fun. Initially I had no spark as the knock sensor and crank sensor use the same plugs which where on the wrong way around!Then I had the case of no fuel where the fuel lines were on the wrong way around also. But then re assuringly the 6 pot fired into life.So plans for the car :1) New intake setup - currently the car can stumble a bit as rolling into boost and I wonder if this is a cause of the MAF. I could also do with a vane for the MAF to try and smooth and control the airflow better.2) There are 2 nasty bends in the intercooler pipeing that need to be sorted also.3) Extra exhaust silencer as I like the car to be even more of a sleeper Managed to also give the car a quick clean. Car is running okay but has a big stuttering problem. Need to track it down and see if its turbulance in the MAF or fuel delivery related.Also need to investigate short runner intake as the manifold gets very hot sitting so close to the turbo. Link to post Share on other sites
Swivelonit 119 Posted August 23, 2013 Report Share Posted August 23, 2013 Interesting read mate, I see you are running the standard inlet manifold which I think is plastic, also turbo charged, I didn't see a head spacer for compression dropping so I can only assume you are running low pressure boost from the turbo, out of interest what psi are you running and what HP increase do you think you have achieved? Link to post Share on other sites
AJmk2 2 Posted August 26, 2013 Author Report Share Posted August 26, 2013 Spec on engine is :8.5:1 spacerUnited motorsports 4" MAF & Base map. Running approx 5-6 Psi at the moment while checking the car over but the previous owner had it at 1 bar and dynoed 341 WHP.I think there is more to come out of it with a few changes to intercooler pipes and exhaust and a updated map. Link to post Share on other sites
Swivelonit 119 Posted August 26, 2013 Report Share Posted August 26, 2013 Thanks for the information, I am hoping to add the turbo bits over winter to my MK 4, I have most of it just need a spacer, although I have been told 6-7 psi is ok to run without dropping compression, so I might try this first. Then progress to head off and boost increase, injectors etc. Link to post Share on other sites
c00k 435 Posted September 6, 2013 Report Share Posted September 6, 2013 Very nice car Link to post Share on other sites
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