Jesse888 Forged/stroker turbo ek9


Update,
Got the engine in!
Gearbox going in tomorrow and hopefully have almost everything ready to run for when the pump turns up.

 
Good stuff! Not long now!
How come your putting the box in separate?
 
Yeah me too! My life's consumed by this car at the ring!!
 
I found doing it with the box on but inlet mani and a bit of bracketry off quite easy, get a bit more angle on it then and fitting the inlet mani is lighter work than a gearbox
 
I only had a hoist and a tow rope lol getting the right angle was a major pita.
Having the whole engine on abit of rope was abit sketchy. Held up ok though.
I'm ok getting the box in. Done it so many times it's easier than an inlet mani to me now lol
 
So Sod's law after saying I find gearbox swaps easier than intake manis I get a pig of a gearbox job lol
Such a battle with this and getting it to line up with all the mounts etc.
Managed it in the end and I got all gears on the gearstick.
Just smaller jobs now so shouldn't be too much longer!
 
Decided to get back out there and fit some more parts
Radiator and filled with coolant.
Intermediate shaft
Run a power wire for a battery relocation
Boost pipe
Got the breather catch can fitted to the rear ports, will for front ports when the turbo gets fitted.
Small bits and bobs left really. Waiting on that pump!
 
Got some good news. My pumps been sent today. Doubt I'll have it before Xmas but could well be between then and new year.
 
Good stuff! Some times gearboxes on these are just a right bastard for no reason other times they slip on so easy, just pot luck I guess,

If your ever short of rope for lifting engines I find old seat belts with the ends cut off excellent, I've craned out many engines using seat belts
 
Yeah that's a smart idea. Got some spare belts aswell.
 
Update,
Wired injectors in.
Then had time to fiddle about, so had a look at the plumbing for the wastegate setup.
Came across the T-piece used to supply the boost controller(then on to top wastegate port) and bottom wastegate port with a boost signal.
It's melted shut.
What this means to those not into turbochargers is that the boost was not being controlled anymore, the wastegate became a bung and forced all the engines exhaust gas through the turbocharger, creating more and more boost until it blew the engine up.

Plastic t-pieces are common place even on factory turbocharged cars, I've obviously plumbed mine in alittle too close to the turbo and while on the cool down from the lap before (sitting in car park) it's slowly warmed it up and melted the ends shut.
So I could have saved the engine and all this trouble for the cost of a brass t-piece (£2.65) or just plumbing it further away from the heat source.
If you ever meet me in person, feel free to beat me with a large torque wrench!
 
In other news. Oil pump arrived today!
So it's just oil cooler and remap!
 
Oh dear! Although it's alway nice to find the cause of a problem it's a shame it was such a silly little thing,
Live and learn I guess! At least you've got a nice fresh engine that should be stronger now
 
Yeah abit of an amature mistake really,
Was less than 6" from the turbine housing. Lesson well and truly learnt!
On the plus side I've learnt so much over the last few months building this and I've got a really nice sense of achievement ATM, if the new engine works as planned I'll be chuffed either way.

Got new pump on, sumps back on and Cambelt timed up, covered up and pulley on.
Driveshafts in and I heard the LSD clunking for the first time is months while tightening wheels down etc.

Got to try out the steering weight with the engines weight over the wheels.
Amazingly light considering I'm dry steering. Not going to have an issue with that I don't think.

So hold ups are oil cooler,gearbox oil(not yet purchased) get the turbo on and then a remap to run the new injectors/map sensor. Then it can start and hopefully run!
 
I don't think that lead to your engine failure. I imagine your tuner would have put in place a boost cut limit meaning if you experienced a over boost condition the ecu would take action to protect the engine, normally a hard cut limiter.
 
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