Biopowered - vegetable oil and biodiesel forum
Biodiesel => Vehicles => Topic started by: lozzzzzz on May 16, 2014, 07:44:53 AM
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When I tell people my plan for this car, 9 times out of 10 I get a negative response. I'm hoping it might be different on this forum :)
I like a project (see the Scimitar in my other thread). Knowing about bio, I have to have a diesel car, but I don't like front heavy hatches so here's the plan. MR2 TDI, using a 110hp pump pre 98 VAG engine. I love the MR2 and the engine is a strong-un and can be made to be a little more pokey with a minimum of effort.
This has been the plan for a while. I've been casually looking out for a suitable car, not really wishing to buy one yet. Then this came along at £300.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/c7cf1bac-de4e-4138-b6f1-b0721e5dc3d7.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/c7cf1bac-de4e-4138-b6f1-b0721e5dc3d7.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/14d46e90-62f9-47b8-b2f8-70515b5659f4.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/14d46e90-62f9-47b8-b2f8-70515b5659f4.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/6d8d1af6-4310-4604-95d5-6d538da7671c.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/6d8d1af6-4310-4604-95d5-6d538da7671c.jpg.html)
Its a 1991 with MOT till November, and tax for this month only, 84k miles and pretty good underneath. There are some dents and a tiny bit of rust. Its off to the garage to have its rust "nipped in the bud" then in a couple of week I'll get it back and start unpicking a 110hp tdi motor from a boring Sharan or Galaxy or something.
I CAN'T WAIT
Guess I should finish the bio rig first:)
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That looks a bargain I you have to many projects I think you need to concentrate on the bio and pass that on to me. For what my opinion is worth I think it will make an excellent fun economy motor.
BTW You need to win the lottery so you can give up work! Mind you I seem to have even less time since I retired.
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Nothing wrong with a diesel sports car just look at the recent LeMans winners.
I prefer the previous model, the squarer one.
Anyway someone put a merc lump in a Roller creating the first diesl model.
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Go for it I say. Some diesels kick out serious BHP. Especially when mated to a lighter body.
Wish I only had the time and space to work on one.
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Well it is now insured! I'll be enjoying it in a couple of hours, then not seeing it for a month or two.
Can't wait to drive it again.
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That's a beauty for £300. :) Go for it!
Sure you can't be tempted with this for £500?
http://www.ebay.co.uk/itm/MERCEDES-E300-3-0-ENGINE-DIESEL-606-962-COMPLETE-WARRANTED-/350958288234
24 valve 3 liter turbo = 175 hp :)
No idea how you'd connect up the transmission though...
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I think you've got yourself a proper project there Loz.
If the 110bhp engine is anything like the one that was in my passat it'll go like stink. Great engine...dodgy turbo..but great engine.
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Nothing wrong with a diesel sports car just look at the recent LeMans winners.
I prefer the previous model, the squarer one.
Anyway someone put a merc lump in a Roller creating the first diesl model.
I had the previous model, petrol, long before i had even heard of bio, lovely motor, like a roller skate :)
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I had this model 2.0 twin cam, brill motor 35 mpg all day long however I drove it. And I drove it. No speed cams then. Great stereo as well. 4 years of ownership not one problem.
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Scimitar where?
I have a scimitar, still in bits
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Looks like a good project.
I remember a few years ago there was a bit of a thing about sticking diesel engines in XR2s and XR3s, usually a smoky old Ford 1800 TD out of a rusted out Escort van.
I was never very taken on the idea.
A tidy diesel in a car like that is a different story all together.
I wonder how much weight difference there would be? A relatively old petrol, against a more modern diesel. Maybe not all that much.
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I'd like to say the car did the hour journey to our trusted body shop man, but it ran on two cylinders most of the way....... oh well don't need that engine :)
(I'm sure its just the coil or something, they are good engines, but this one hasn't been looked at for a while)
When considering my options, I looked at that merc, its a cracking car! but the 6 cylinders wouldn't fit in west-east.
I had the 90hp version in my golf a couple of years back, I gave it two years of relentless abuse and it didn't complain once. I'll be popping the 35hp extra chip on there too. Now I'm sure there is a little hype and it might be a bit less than that, but people have said good things about it. So 140hp tdi!!!! that should do the trick :)
The Scimitar was in Practical Performance Car Magazine in January, a 7 page spread :) And there is eveidence that I've spent far too long writing about it myself here:
http://www.pistonheads.com/gassing/topic.asp?h=0&f=149&t=989675&i=0&mid=246798&nmt=Project+Scimitar+MV6
Where are you Rossey, and what's the story with your Scim?
Godd point with the Weight, I could doa before and after as we have a weigh bridge near us.
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I'm in Luton.
It's a father son project that hasn't been finished.
We got two and recon engine for £200
It's a rolling chassis at the mo.
Engines never been run since it's rebuild and is fitted with Kent cams.
I did see a scimitar with bmw Diesel engine in and I'm trying to persuade my dad into putting a diesel in it so I can run it on bio and the car will get some use.
It's se5a I think 1973.
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Sweet!!!! Tax Exempt :) and Bio.... that will be one cheap car to run.
Get it done, the BMW diesel is a cracking choice, do it!!!!
I think I know the car you mention with the BMW diesel, it was up for a sale about a year ago, I think it was snatched up pretty quick on the Scimitar Club forum.
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Diesel MR2, you must be mad.
Only joking it's a great idea.
For some time I've had the thought of a Caterum with diesel power, but would go for a PSA 2.1td XUD11 12 valve,
bags of low down power, bullet proof, good for 400K (if looked after) and responds very well to a tweaked manual Bosch pump (10mm plunger, ground head) and bigger turbo.
The XUD11 is quieter and smoother than the VAG units.
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Loz...if you can get hold of a 130bhp pd engine and then have a blacksmoke.co.uk remap to 162 then you will have a truly awsome motor. Mine goes like a bullet now.
The problem with that merc engine is there is no gearbox. Still has the fluid flywheel but no autobox!!
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As for an engine for the mr2
What about a rover l series?
Mine was 100bhp, I've put different injectors in and increased the boost, now looking nearer to 150bhp.
If you use a vnt turbo 185bhp can be achieved!
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Loz...if you can get hold of a 130bhp pd engine and then have a blacksmoke.co.uk remap to 162 then you will have a truly awsome motor. Mine goes like a bullet now.
Or the older PD 150, just adding on of the Dragon boxes gives 185 BHP.
I drove a standard PD150 golf GT and thought it had no right to be a diesel.
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Or an Audi AKE engine - 180 BHP as standard and mappable to over 200. Plus it's V6 so will fit transversely easily.
Whatever engine you get, if it is electronically controlled (VP37, VP44, PD etc) then make sure you get the ECU and harness too
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Whatever engine you get, if it is electronically controlled (VP37, VP44, PD etc) then make sure you get the ECU and harness too
That's the good thing about the XUD11 with manual Bosch pump, only one wire needed.
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Whatever engine you get, if it is electronically controlled (VP37, VP44, PD etc) then make sure you get the ECU and harness too
That's the good thing about the XUD11 with manual Bosch pump, only one wire needed.
..but it's french. ::)
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Whatever engine you get, if it is electronically controlled (VP37, VP44, PD etc) then make sure you get the ECU and harness too
That's the good thing about the XUD11 with manual Bosch pump, only one wire needed.
..but it's french. ::)
yes it's french, but the best part of any PAS is the diesel engine.
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Whatever engine you get, if it is electronically controlled (VP37, VP44, PD etc) then make sure you get the ECU and harness too
That's the good thing about the XUD11 with manual Bosch pump, only one wire needed.
..but it's french. ::)
yes it's french, but the best part of any PAS is the diesel engine.
Yep the diesel engine is probably the only thing the French got right in their cars, from personal experience it's neither the transmission, the suspension and certainly not anything electrical. Great engine though :)
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Agreed the french make a good diesel, but I've had the VAG engine before and loved it and I'm going with the older unit for its tolerance of badly made bio. :)
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Owners hand book for the PD Golf the wife
abuses drives states that it is designed to run on 100% FAME, and so far it's been as good as gold on 100% bio.
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Owners hand book for the PD Golf the wife abuses drives states that it is designed to run on 100% FAME, and so far it's been as good as gold on 100% bio.
Which engine is in the golf that she abuses Julian?
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Owners hand book for the PD Golf the wife abuses drives states that it is designed to run on 100% FAME, and so far it's been as good as gold on 100% bio.
Which engine is in the golf that she abuses Julian?
I think it's a 90bhp version, I'm afraid I struggle to show much interest ... it's only two wheel drive.
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I think the 90 is a non pd. It must be something else.
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It's a 2004, the hand book says 74Kw so it looks like 100Hp ... Engine code ATD (big space) EUH.
Whatever it is it, goes like stink and I don't think hers is the most powerful version they do.
While on the subject, has anyone got a code reader for this car? The alarm keeps going off and I can't work out what's causing it. For now I've pulled a fuse which has disarmed it but also stops the windows and central locking working.
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I have vag com but it is a long way from you!
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I have vag com but it is a long way from you!
Thanks Dick, kind offer, but as you say distance is a problem.
I bought a cheap cable off ebay and downloaded the "lite" version of vagcom think it's called VCDS or similar now. The cable seemed to be recognised by the laptop, as was the fact it was plugged into a car, but the VCDS didn't seem to want to work. It does some test on the cable for signal strength (didn't think signal strength was an issue with digital signals ... it's either there or it's not) anyhow, VCDS didn't want to work.
Add to that I suspect the age of the car might put it just prior to OBDii being use in the UK. Plus I think the codes I need are on the CANBUS system rather than OBDi or ii, it's all bloody confusing. Pulling the fuse is my kind of fix.
Although money is a bit tight at the moment some sort of reader would be good investment, it's just knowing what will work on what car before splashing out.
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Perhaps you should bring the Golf to the BBB....at least you guarantee getting there and back. Something not assured with a lawnrover.
I know that Jules has the full vagcom soft ware. He tried to intal it on this pc last year. I havn't been able to get it to work but I'm sure it's something to do with me rather than him 8)
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I'll have you know it was commented last year, not by me, that mine was the only Land Rover that made it there and back without fault.
I'd like to try and sort it before the BBB but if I haven't, I'll contact Jules and see if he would mind bringing it along.
From what I've read, you only get a couple of installs of VCDS (what ever it's called) before it locks, so as unlikely as it seems, it may not have been your fault.
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Julian
Have you tried the boot switch had the same problem with passat estate the rear wash steel tube runs through wiper motor this splits and fill the switch with water . Try take out dry and contact cleaner
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Julian, I have sent you a PM
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Julian
Have you tried the boot switch had the same problem with passat estate the rear wash steel tube runs through wiper motor this splits and fill the switch with water . Try take out dry and contact cleaner
I've replaced the drivers door lock, that seemed favorate from what I read. What a parlava to get out, you've got to take the window glass out to get to it. Inside there are no less than 5 microswitches! Found a new patten one for 20 quid, fitted it and .... just the same.
Boot switch was next on the list. Are these cars built well? The door and boot trim is fixed more securely and stronger than front wings on many other makes. Eventually arrive at the boot switch and it looks fine, no water marks etc. What were the external indications that the boot switch was to blame ... or are you talking about the wiper motor fillingwith water?
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Julian, I have sent you a PM
Jules, you're a diamond, you have a reply.
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Hi Julian
It was the boot switch which was activating the alarm every time you press rear wash it fills the switch up with water when the steel pipe is twisted and splits.
Have you got the small switch on the drivers a post that switches off the sensors?
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Hi Julian
It was the boot switch which was activating the alarm every time you press rear wash it fills the switch up with water when the steel pipe is twisted and splits.
Have you got the small switch on the drivers a post that switches off the sensors?
I'll check out the boot switch more carefully. Don't know about the switch on the A post, I'll check that out tonight.
Thanks for your help.
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Picked this up today, I have lots less money but the car has lots less rust :) :)
It is in fact rust free :) :) the bits that haven't been sprayed need a good polish to match the new paint and the wheels look crap at mo, but I'm really pleased and can't wait to get stuck in :)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20140704_165846.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20140704_165846.jpg.html)
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I finally have an engine :) :) :) :)
I'm really happy with my purchase and think I've got it a at a reasonable price. It's a 1999 seat toledo with a 110hp AHF engine. soon to run out of MOT and Tax but still legal long enough to get it home. It has 89k on the clock and cost £450.
I've not had long on it due to starting a new job that entails rather a lot of commuting, but here is the progress so far. I've just been stripping the loom, and labelling.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20140830_104918.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20140830_104918.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20140830_104928.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20140830_104928.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20140830_104943.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20140830_104943.jpg.html)
Its one fo the very last distributor pump type TDI engine from VAG and can be tuned plenty :)
I want to get it running on the garage floor, then carefully strip away all the parts I don't new leaving the engine loom and instrument cluster, and hopefully adding a cruise control stalk for good measure.
I plan to:
Bin the dual mass flywheel in favour of the G60 solid flywheel and VR6 clutch (can take 300ft.lb)
port the head and regrind the valves for good measure
fit a new water pump and cambelt kit
fit a "tuning box" for 140 + hp
then later when all the problems are ironed out
Fit a PD130 turbo and manifold and larger injectors and a larger intercooler to get it closer to 180hp
I can't wait, its great to get started on a new project.
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Nice! Daunting amount of work (I used to have a kit car until we had kids!)
Love seeing project photos at it goes along, thanks for sharing so far :)
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Gonna be a great project.
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That would be a fantastic project. You'd need a ford type9 diesel gearbox for long ratios and rear drive, but that would be do-able :) There was a few articles on a westfield diesel in PPC magazine, they called it the wiesel!!
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Got some more done last night, nothing major to report other than I set the small target that I set myself and removed the last of the loom from the interior (not yet the engine bay though).
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20140901_212157.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20140901_212157.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20140901_212151.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20140901_212151.jpg.html)
It just needs feeding through the bulkhead when the engine side is disconnected.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20140901_212136.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20140901_212136.jpg.html)
I didn't really show a very good pic of the engine before so here it is:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20140901_212127.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20140901_212127.jpg.html)
Sorry for the crappo pics, I'll use the SLR next time.
Work starts on the engine loom at the weekend.
More to come
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Hmm. I hope you remember where all those plugs go :)
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I got some more done this weekend, between jobs on the 106 :(
I've finally got all the loom out and labelled everything up. I've got a nasty feeling there is no speed sensor on the gearbox at all, I imagine it must use one of more of the ABS sensors :( thats a bummer as I've cut them all off.
Anyway, progress so far.
The loom is now completely free from the car and all the bits I need (minus the ABS sensors) are in tact.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture002-4.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture002-4.jpg.html)
The engine is nearly free and ready to come out:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture001-3.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture001-3.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture003-3.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture003-3.jpg.html)
More to come
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Rather you than me.
I struggled this afternoon with eight bolts to remove the front prop from the Disco!
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Definitely an automotive epic adventure. The final result will certainly be quite unique :)
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Tony, we neeeeeed pictures of your old kit car.
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Oh crikey, they're on 35mm film under the bed somewhere!
The internet is amazing though, there's pictures of a couple of them here:
http://www.allcarindex.com/auto-car-model/United-Kingdom-Lightning-1-Targa-Sport--TS/
Mine looked like the white one on the right, but in black.
It's pretty amazing there are pictures on the internet considering that only 10 kits were made (and one of which was soft top). Mine had the 2 litre Pinto engine in but this was replaced with the Granada 2.8 V6.
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Looks like a Corvette, very nice.
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I like it, I'd have to go with the slotmags rather than the wheels on the red car though.
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I'm really wrestling with time at the moment, the new job requires 7 more hours a week than my last job and its an hour away where the last job was 11mins. That and making bio has meant a huge reduction in car time :(
I'm working on it though (getting more time and the car)
The engine is finally out :) :) :)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture005-5.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture005-5.jpg.html)(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture006-4.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture006-4.jpg.html)
There are a few more bits to harvest from the toledo then its off to the scrap yard in the sky:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture004-5.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture004-5.jpg.html)
There is a nice DOC to sell under there somewhere. There diesel in the tank to extract and some sections of exhaust might come in useful too.
I'm still undecided on which direction to go now. Strip the loom, learn more about the MR2 loom, or just get stuck in stripping and tuning the TDI motor first???
Well I've got to stop the scimitar exhaust tapping on the floor of the car first and fit new track rod ends to the pug. But hopefully in the not too distant future I can get a solid 8 hours on this.
More to come
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Oh to be young with the drive to undertake something like this.
Can I scavenge a rear caliper and carrier off it if they are any good? I assume you are using all the sensors? Has it got remote central locking?
Don't forget to clean the turbo inside before you put it in the MR and check the actuator as they force limp mode for a pastime.
Are you using the intercooler from the vag or the MR?
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I can have a look at the calipers for you no problem. I believe its the same car as yours underneath you're welcome to bits more if you want. I'll be using all the sensors associated with the engine yes.
The MR2 was an NA, I'd llike to fit a massive intercooler as its a no brainer in terms of getting more power, but this is something of a packaging problem on a mid engined car, so i might stick with the VAG one and put in in the little side vent that the MR2 has.
As for the turbo, I though it had your name on it. :) I might hang on to it for a while, at least until I get a PD13-.PD150 unit. But at that point the turbo is yours if I can borrow VAGCOM for a while.
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I spent most of this morning pulling the last few bits off the toledo, the first length of exhaust pipe, the gear linkage and a few nuts and bolts. I put the bumper back on, and the bonnet. Drained the tank and put it in the daily driver.
Then out came the Scimitar and in went the MR2. I've taken a few bits off it and had a good look over it. I think I'm going to do something like what I did with the Toledo. Label everything up as I disconnect it, take the engine and box out, then open up the loom and check there is nothing in that stretch of loom that I need.
So this is where I'm at at the moment. It still doesn't look like much progress, but I really have run out of other things to do now :)
This might sound strange, but I really like working on Toyotas, this is the fourth Toyota I've worked on and they just seem to be so well put together. Everything is in a sensible place, well made with dimple topped captive washer bolts, and all rather well thought out.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture010-3.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture010-3.jpg.html)
More to come.
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It's the Japanese way. In my experience they come apart easily, even after years, and are designed to go back together correctly. Can't say the same about the European cars.
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Yes I'm with Dick on that one, Jap cars are the way to go when it comes to mechanics designed with maintenance in mind.
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I took a day off today and was in the garage all day :) It was like old times, a pig in s*** :) :) :)
I made another 150L of bio diesel. I stripped the Toyota engine loom in an attempt to understanding it and see if I could get the engine bay fan to work in the absence of the engine (I couldn't). So the engine loom now consists of just the reverse light wiring :)
Then stripped the loom to the dials and have identified what I need to make the following warning lights work: main beam, fog lights, handbrake, doors open, and indicators. Then took it to pieces and was delighted to find that the VAG dials will fit in the gap where the Toyota dials used to reside. Result!
As well as that, I've done my usual looking at it for ages and figuring things out, got lots of ideas in my head now. What a great day! :)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141009_201104.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141009_201104.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141009_201054.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141009_201054.jpg.html)
More to come
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Isn't it wonderful when progress is made?
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Coming along.
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It certainly is good :)
no progress this weekend to report, but the missus did organise a surprise party for my 30th and got me a tank driving experience :) :) She's a keeper!
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Ooh, nice one :)
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A little update on my (lack of) progress :)
I've not done a huge amount as the clutch on my cr**y 106 diesel failed in a way that meant it wouldn't disengage. So I've taken the gearbox off that and am waiting for a new clutch plate to arrive.
Spot the piece of metal where it shouldn't be......
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture002-5.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture002-5.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture001-4.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture001-4.jpg.html)
On the plus (but rather expensive side) I'm driving the scimitar 90 miles a day, getting plenty of admiring looks and really enjoying the car (at 5 times the cost!!!).
Back to the MR2, I've been doing a bit of loom thinning, this time its the TDI loom, its about halved so far, I need to go get some of the controls to keep going with the job now.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/IMG-20141019-WA0001.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/IMG-20141019-WA0001.jpg.html)
More to come.
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Keep at it. There will always something else that comes along and stops you doing what you want to do, or there is in my experience.
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It Runs!!!!!!
After several weeks of head scratching, a friend at work gave me a circuit diagram from autodata (thanks Mark), and it seems I had an earth connected up to 12v. I changed that and it ran straight away. See the video here:
https://www.youtube.com/watch?v=O6V9oazx_HI&feature=youtu.be
Its very nearly in a position to be electrically connected to Mr Two now, I hope to have that done soon, then I'll get started on the mechanical side and physically putting all the wires in the car.
Very happy with that.
More to come.
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Well done. I hope those are not methanol drums at the back of the workshop with all the sparks about!!
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Impressed, it sounds lovely the way it is, a bit like a nice calm canal boat ... bet it won't sound like that under load in the car.
Keep up the good work!
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Tidy. If I did that, the engine would take off across the workshop floor.......
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Dick,
Hmmm, maybe :(
I'm quite liking (loving) the sound of the turbo whistle, particulary the way it slows down gradually after the engine has reached idle. I'll try to keep that sound in the car I think.
I was worried the engine might run away so I put it on a lead (an old seat belt)
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Surprisingly strong, seat belts. A friend of mine got towed a few hundred miles using one as a tow rope!
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Another small update. The rough running is sorted, and I've been working on the tank.
Got it off the car:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141130_122057.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141130_122057.jpg.html)
Cut off the toyota float, and fixed the swing arm in place, then attached the TDI tank sender to get the right signal to the dials.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141130_124024.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141130_124024.jpg.html)
Then had to put it back in in a different orientation so it could still move up and down freely:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141130_122948.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141130_122948.jpg.html)
Then pulled the impella out of the fuel pump so its now effectively a pipe:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141130_121943.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141130_121943.jpg.html)
And re-assembled it:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141130_122050.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141130_122050.jpg.html)
I've got a new cam belt, water pump, oil filter, fuel filter and oil to change, then the MFA/cruise switches to wire in then the loom can finally start going into the car.
In a break from MR2 stuff….
The Scimitar ran out of tax yesterday. As a little treat, I took it up to Rhayada for a late night blast. It was a lot of fun, not another car for miles :) :) :)
Hope you like the photos. (fireworks was taken on bonfire night)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture132.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture132.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture146.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture146.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture138.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture138.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture139.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture139.jpg.html)
And for the grand finale (this shot took a long time and included an 11 min exposure):
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture144.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture144.jpg.html)
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That's very cool. On the last one what was the single light that left the trail?
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Thanks Tony! It was me :)
I ran across the dam with my HID torch to illuminate the road and walls (torch facing away from the camera)
Then I ran back with the torch on my phone (facing the camera) to give that line.
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Impressive, talk to Angie she has a photography degree.
On the MR. If the strainer is not easy to clean when the tank is fitted you might want to remove it and fit one that is easy to get at as they can cause problems when on bio.
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Its completely installed again. I have a plan though..... If/When it causes a problem I can attach it from the fuel sender hole (can be accessed from inside the car) and put a big hole in it or get it off.
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Hello again. I've made quite a bit of progress recently but haven't really had time to post about it. Well here is a bit of an update.
I've changed the cambelt, idlers and water pump (but was disappointed to find they were in really good condition so could have saved a load of money)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141203_193942.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141203_193942.jpg.html)
I've cut of the bits I don't need leaving just the tensioned and alternator:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141203_204104.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141203_204104.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141203_204120.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141203_204120.jpg.html)
Next was to sort out the horrendous throttle and EGR situation. The crank case gas recirculation means that oil makes it into the inlet and the EGR means that soot gets in there too, the combination means an epic building up of black crud (you can see it in the photo below). The already small inlet pipe had 8mm of caked on crap so that was cleaned out. The EGR was welded up (using bird poo, check out that weld) and the throttle and EGR valve was binned. In fact I went further than that and cut the elbow of the manifold completely. (The throttle is only used when the engine is switched off, it creates an inlet manifold vacuum, just like in a petrol car. Less gas in the cylinders means less compression and the engine spins gently to a stop, rather than the abrupt shaking you can get with older diesels. I can live with that for more power.)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141205_104633.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141205_104633.jpg.html)
Imagine the restriction this was giving:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141205_104657.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141205_104657.jpg.html)
This is after cutting:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141205_104633.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141205_104633.jpg.html)
I then cleaned and ported the manifold a little and used the rubber hose straight onto the manifold:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141205_104750.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141205_104750.jpg.html)
All done:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141205_104811.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141205_104811.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141205_104819.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141205_104819.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141205_145923.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141205_145923.jpg.html)
I've found a 760mm belt to drive just the alternator:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141212_074336.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141212_074336.jpg.html)
Yesterday I started messing about with the intercooler to see if I could get it to fit against the MR2s side duct. The plan being to use a micro switch under the throttle to switch on the fan and pull air through the intercooler on full throttle.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141212_083410.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141212_083410.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141212_083424.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141212_083424.jpg.html)
Its still not perfect really, I'll keep pondering this one.
I tested to see if the throttle pedal feel was ok if I just connected up the MR2 pedal to the TDI variable resistor.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141212_112517.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141212_112517.jpg.html)
It was great, good pressure needed to push it (it just supports the weight of your foot) and a decent amount of travel (a little less than previously but still plenty for accurate control). So I welded a more permanent version into the under bonnet space.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141212_152436.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141212_152436.jpg.html)
And the last thing I got done yesterday was to attach the clutch pedal switch on to the MR2 clutch pedal (as I plan to have cruise control).
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141212_162854.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141212_162854.jpg.html)
Sorry for the crap images, I was using my phone again. I'll take a better camera next time.
More to come
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Good progress I hope you have some heat in that workshop, I try to avoid car work this time of year. Mind you as you know I work outside.
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Cool
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I made a bit more progress last night.
Lots of grinding away at the old MR2 dials, trying to get the TDI dials to fit inside. On paper that sounds like very little progress, but.. I did spend a while looking at it and figuring out how it was all going to come together. I'm pretty sure I know how to finish the interior side of things now. The dials are officially in (although the dead space either side of the TDI dials still needs painting black). I'm going to have a number of switches on a panel in the spare space above the radio (its double height), including the MFA, cruise control and perhaps a switch for the little power booster thingy (resistor).
Very pleased with progress I was too.
Forgive the dust all over the clear plastic, I haven't cleaned anything after grinding yet:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141217_212833.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141217_212833.jpg.html)
More to come
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:D
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Right then! A much needed update.
I've got the dials looking how I want them to now, and they're fully wired in, and fully working :) But as I was putting them in for the last time I cracked the Clear plastic (the toyota bit). I'm a little gutted but this can be easily replaced at some point when I have more money to spend. (you can't see it very well in the photo but the crack goes from the top down through the speedo)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141226_063535.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141226_063535.jpg.html)
The illumination adjuster now serves no purpose so I've blanked it off.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20141226_063515.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20141226_063515.jpg.html)
I've reached a point where I really need to get the engine in before any other work can progress. So I cleaned up the garage and lined the engines up to get an idea where the TDI will need to sit in the engine bay.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture002-6.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture002-6.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture001-5.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture001-5.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture003-4.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture003-4.jpg.html)
Then set about making the first engine mount.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture004-6.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture004-6.jpg.html)
I got these bars to the same length and flattened the ends on the lathe:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture005-6.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture005-6.jpg.html)
Drilled them out on the lathe:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture007-4.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture007-4.jpg.html)
These will mean I can use the same three bolt holes that VW intended:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture006-5.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture006-5.jpg.html)
Cut a plate to shape:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture008-4.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture008-4.jpg.html)
And welded on the engine mount:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture009-4.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture009-4.jpg.html)
This is ready for a trial fit on Sunday (I'm very excited), if all goes well I'll start looking at the gearbox mount and add some bracing to this mount.
It is with regret that I'm altering the budget of this project, I'm now having to reduce costs as much as possible. This mainly means it'll be on the rather nasty 14" wheels for a bit (the gearing will be 5% down, i.e. more revs for the same speed) and the engine tuning will be in the form of decat, decoke and fit the +35hp "chip" (resistor). it should still match the brothers fabia VRS though :)
More to come
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Going well. What's this +35hp tweek?
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http://www.ebay.co.uk/itm/Performance-Chip-Tuning-Box-SKODA-Octavia-SEAT-Leon-1-9-TDI-35-BHP-90-110-BHP-/190961556659?pt=UK_CarsParts_Vehicles_CarParts_SM&fits=Model%3AOctavia&hash=item2c76321cb3
That's the one I've got.
I think it interrupts the signal to the ECU from the pump to feedback how much fuel is going in. The ECU thinks less, so ups the fueling.
I think this will upset the MPG reading though, so I'm going to wire mine in one a switch so I can turn it off to measure MPG.
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That's interesting, it must fiddle with the quantity adjuster feedback signal. The quantity adjuster itself usually has a relatively low frequency (but high power) PWM signal driving a coil that rotates a spindle against a spring. The lower end of the spindle has an offset pin that engages in a hole in the top of the control sleeve in order to slide it up and down the high pressure piston. But it also has an electromechanical feedback system to detect how far the spindle has rotated, which has two coils, one fed with a high frequency signal and one as a pickup. The spindle has an arm which acts to change the flux connectivity between the signal and pickup so the ECU can figure out how far the arm has moved. So I often wondered how hard it would be to break into this feedback loop for the purpose of changing the fuelling.
On the Largo I took a different approach and modified the fuel temperature sensor (another part of the VP37 bit at the top of the pump) to over-report fuel temp. The ECU compensates by injecting more fuel (as it assumes fuel viscosity reduction results in delivery quantity reduced from the high pressure plunger stroke, due to machining tolerances and increased leakage past the piston).
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Interesting. I must confess that I know very little about how a pump works really, I've always done petrol cars before this. But I follow what you're saying. I should take a pump apart one day :)
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http://www.ebay.co.uk/itm/Performance-Chip-Tuning-Box-SKODA-Octavia-SEAT-Leon-1-9-TDI-35-BHP-90-110-BHP-/190961556659?pt=UK_CarsParts_Vehicles_CarParts_SM&fits=Model%3AOctavia&hash=item2c76321cb3
That's the one I've got.
I think it interrupts the signal to the ECU from the pump to feedback how much fuel is going in. The ECU thinks less, so ups the fueling.
I think this will upset the MPG reading though, so I'm going to wire mine in one a switch so I can turn it off to measure MPG.
Send it back, you can do the same for a quid!
Look up evry mod.
You can also fit a 3 bar map sensor and that'll give more boost.
If you want a tuning box, look up rover Ron vp box.
I've got one on my volvo and it'll wheel spin in third!
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Impressive reading never come across it before. More research to be done.
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I got the engine in this morning. Very excited about that :)
Its only attached by one engine mount and mostly hanging on the crane, but it was a great success in terms of seeing how well it fits and checking where things might go:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture025.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture025.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture024.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture024.jpg.html)
There is loads of room behind, I was worried about this area:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture026.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture026.jpg.html)
Then I took it back out and finished off the engine mount I had tacked on:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture028.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture028.jpg.html)(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture029.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture029.jpg.html)
I drilled out one of the gearbox bolts that snapped off in the TDI gearbox (what a horrible job!)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture030.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture030.jpg.html)
And began making the gearbox mount:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture031.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture031.jpg.html)
That's all for now
More to come
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:)
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Great photos - glad it fits! :) How hard will a cambelt change be - looks close at the front end?
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It will probably be just as easy to take the engine out for a cambelt - all the bolts will be nice and free after the build
Absolutely awesome job there, I dont know too many people who would take on a project like that
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Ah Loz, you are making my memories flood back, I've done a few projects myself in the past, and its funny how jobs that were a right pain at the time and took hours to figure out how to make different parts fit together and work, after its done and running they become almost fond memories, and sometimes if the solution is simple and ingenious become righteous moments, especially 25 -30 years on! if you were nearer to me I would be there helping you.
V8 rover into bedford CF van, same into a transit van, V8 small block ford 289 into v6 mKII (girly) mustang, turned a MKII cortina estate into a pick up, various ford engine upgrades using bigger ford engines, Dolomite sprint engine into a ford Anglia, the anglia had a straight 6 2.4 jag engine and box in when I got it! Used to be a gang of us hung around this mad lockup garages area, always someone doing something mad with a motor and plenty of knowledge/tools/equipment/ideas when you were stuck.
Mind you the stuff we did back then on the road testing half built cars, bikes vans, towing, wheelspins, burnouts, showing off etc we would all loose our licences in one afternoon if we did the same these days
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Thanks everyone, its very encouraging to read comments on the forums, helps keep me going out to the cold garage :)
The cambelt access is a bit better now that it was with the old petrol engine. I'm not sure I'd have changed it in the car with the old engine, but I think it could be done with the TDI now. The engine mount you see in the photo can be taken completely off in situe if the engine is supported of course :)
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Considering the significance of getting the engine mounts done, this is pretty lame update as I forgot to photograph the engine finally sitting in the car with no crane assistance.
Anyway, the engine mounts are now all finished and painted and while I have the stone-chip gun going, i took the opportunity to spray a few little places low down in the engine bay that looked as though they would appreciate some rust prevention.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20032.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20032.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20034.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20034.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20035.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20035.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20036.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20036.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20037.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20037.jpg.html)
Still need to drop the tank one more time and remove the gauze, sort the clutch hose while access is easy then pop it in for the last time :) :) :)
More to come.
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Ah Loz, you are making my memories flood back, I've done a few projects myself in the past, and its funny how jobs that were a right pain at the time and took hours to figure out how to make different parts fit together and work, after its done and running they become almost fond memories, and sometimes if the solution is simple and ingenious become righteous moments, especially 25 -30 years on! if you were nearer to me I would be there helping you.
V8 rover into bedford CF van, same into a transit van, V8 small block ford 289 into v6 mKII (girly) mustang, turned a MKII cortina estate into a pick up, various ford engine upgrades using bigger ford engines, Dolomite sprint engine into a ford Anglia, the anglia had a straight 6 2.4 jag engine and box in when I got it! Used to be a gang of us hung around this mad lockup garages area, always someone doing something mad with a motor and plenty of knowledge/tools/equipment/ideas when you were stuck.
Mind you the stuff we did back then on the road testing half built cars, bikes vans, towing, wheelspins, burnouts, showing off etc we would all loose our licences in one afternoon if we did the same these days
I have done a bit of messing about like that, I used to rent a shed in a breakers yard so temptation was never far away, silliest one was a 455ci big block Buik v8 into a Bedford CF ice cream van, complete with a line lock to the back brakes and a diverter flap in the exhaust so you could run on open headers. Oh the noise!
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Looking forward to seeing it all in place and turning a wheel under its own power. Can't be too far away now?
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Mega stuff. Must be seeing light at the end of the tunnel now.
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Thanks folks :) :)
Yeah there isn't too much to do now, certainly well over half way through.
Drop the tank again and get rid of the guaze
extend about 15 wires up to the dials
make the switch panel
put the radio on (normal not boy racer!)
mount and connect the intercooler
put the collant tank in and plumbs it in
mount and plumb in the air filter and feed to the engine
bleed the coolant system
mount and connect up the filter
Get the drive shafts made and fit them
MOT :)
Actually there is still quite a lot!
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put the radio on (normal not boy racer!)
C'mon, you'll need a mighty sub to hear your music over the diesel engine :D
I think I had the epiphany moment of "this is a mid-life crisis" when I couldn't turn the music up too loudly because it made the curtains blow about in the minivan.
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The engine is in, hopefully for the last time. All the mounts are firmly fitted.
I did find a problem though. I had made the gearbox mount with the clutch slave not attached and guess what, it didn't fit. But after some adjustment all is well.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20047.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20047.jpg.html)
This is the third mount that stops the engine rotation, I'm a little concerned that the rubber bush is a bit rigid and might transmit a too much diesel vibration into the car, time will tell!
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20048.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20048.jpg.html)
The clutch hose is all plumbed in, I'm really please with how easy this was (perhaps that temping fate as I've not bled it yet :) )
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20049.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20049.jpg.html)
And a couple of shots of the engine in its new home:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20045.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20045.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20046.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20046.jpg.html)
One of the things that was bugging me was how to mount the intercooler. Well that's sorted now :) :)
These are the bits that need holding together (the black plate with the big hole mounts to the car body).
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20038.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20038.jpg.html)
It turns out they fit together quite nicely. Two of the fan mounts line up perfectly with two notches on the intercooler, holding it in place, its like it was meant to happen :)
So I've attached a strap and a bolt to tighten it against.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20041.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20041.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20042.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20042.jpg.html)
And painted it.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20043.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20043.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20044.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20044.jpg.html)
That's all for now. There are some reducers on the way so I can connect up the boost piping, then I'll put it in place and start the more plumbing or wiring.
Was a good weekend, I felt like I've made some good progress :)
More to come
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Sounds good keep at it. Did you clean the turbo?
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Thanks buddy :) :)
I'll give the turbo a clean when its running, so I can blow it through shortly after.
Any chance I could pop round and have a look at your octavia engine, I've lost track of which connector does the turbo actuator. Perhap I could pick up the booster thingy while I'm at it?
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No probs, come when you like. Car is usually here but best ring first just to make sure.
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This weekend I exploded a tractor battery in my face and spent hours in A&E having bits of plastic pulled out out my eye and checking for acid damage! Now I have 11 drops a day :( :( and I owe the parents £130 for a new tractor battery!!!
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150207_184600.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150207_184600.jpg.html)
Brilliant!!!!
Luckily my vision is clearing up, a lucky escape!!
More to come
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Oooo, nasty!
I've got a hatred of batterys, after seeing one go bang in someone elses face when I was a kid.
Always screw my eyes up tight when I put a terminal on or off.
Hope it all heals up OK. Nasty old job that.
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More to come
Not exploding tractor batteries I hope!
Glad to hear it looks like you survived OK and are on the mend, but how did you manage to do it?
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Thanks Folks.
I was being a total idiot and checking that it had the punch to start the tractor by dropping a spanner over the terminals.
What a tool!!!!!
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You were a bit unlucky there. You could do that a thousand times, and not have it blow.
You watch, in a few days time, all the clothes you were wearing will develop tiny little holes all over them.
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I've seen a 36v forklift battery explode from about 5yds, what a bang and mess, not much left of the battery cell tops either.
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It happens. I had one blow in my workshop at school. Took the charger off without disconnecting. Had to strip off and sluce in the sink to the amusement of the pupils. Damn hydrogen.
Hope it clears up soon.
What did a & e do?
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I couldn't see out of that eye at all, so I felt I should go. Something solid hit my eye at quite a pace too, there was lots of plastic in there, so I wanted to make sure none was stuck in.
A&E were pretty quick really, they washed it and checked pH, then inspected all around and got all the plastic out, then dilated the pupil to check the retina, half an hour later they had a good look in. I have a massive pupil and a bright light in my eye, much fun!!!
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That's nasty that is. Glad your sight survived.
My brother had a battery explode in his face when my dad was cranking the car with his head over the engine bay. Eyes washed out quickly but couldn't hear properly for weeks after the bang.
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Very lucky there Loz,
my mate had battery explode in his mini boot, a few weeks later it looked like someone had taken a shotgun to it.
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Had a good solid day on it yesterday. I was really picking the pace up towards the end of the day as I seem to be approaching the next milestone.... Starting the engine in the car. (not quite there yet mind)
I've got the wires from the engine bay through the bulkhead.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20050.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20050.jpg.html)
And all of the carpet and trim back in, just the box lids left to attach (well in the back anyway).
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20051.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20051.jpg.html)
The ECU now sits in the cubby hole behind the passenger.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20052.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20052.jpg.html)
And I've started extending the remaining wires to meet up with the dials in the front.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20053.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20053.jpg.html)
Jobs left to do before I can start it in the car, are:
Finish extending those wires
Mount the fuel filter and connect up the lines
Put some Bio in the tank
It might go then :) But could still do with:
Air filter, MAF sensor, and boost plumbing finishing
Exhaust connecting up
Coolant hoses connecting up and bleeding.
Exciting!!!!
More to come
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Continues to go well.
I assume the eyes are now good? Has it affected your sight?
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Nice nice nice, must be getting excited about hearing it run even if it's dry and without some of the sensors, that's a real moment that is :)
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I can't wait :) :)
The eye are good, 99.5% back, I sometimes notice something when I first wake up but its getting less each day. In fact looking around now, I don't think I can see any blurry bit at all now :) :) Very lucky :)
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I got the last of the wires connected up and just had to give it a go :)
There are a number of sensors missing, no exhaust, lots of air in the fuel lines and a flat battery, but it soon came to life :)
Two milestones left, Moving under its own power and the MOT :)
https://www.youtube.com/watch?v=tq8LjXg2SEs
More to come
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:D
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I'd have a chuckle too seeing that fire up, nice one :)
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Great that it runs, that must make you feel like it was all worth it. Is the battery a bit low or is the engine a bit tight? It certainly doesn't turn over as fast a I would have expected.
Alternatively, did you use the petrol engine battery cables and earth straps? It could be that they are man enough for a low compression petrol engine but are causing a bit of voltage drop when subjected to the current a diesel starter motor take
EDIT - I have just read your post again and notice the bit about a flat battery - DOH!
Anyway, the point re the started motor cables may still be worth considering if you haven't already
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I'm itching to watch it, but I'm short on top up, and I need what I've got today.
Love the sound of an engine with no exhaust.
I'll have to wait till tomorrow.
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When I built my LandRover Series III trialler 20 years ago, I was so excited that the engine was in and ready to run that I had to start it up and drive it up and down the private track to my parents house
3.9 litre fuel injected V8 petrol with just the exhaust manifolds, no downpipes and free flow air filter.
It sounded something close to a spitfire and blew flames out of the manifolds when I lifted off the throttle quickly
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Awesome :) there is little more exciting, than breathing life into an engine.
Don't get to excited about the video, it sounds like a single cyclinder field marshal!
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Or a Lister?
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The lister sounds better than that :)
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Awesome work, well done.
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I've been so busy, I've pretty much had two weeks with no garage time :(
But yesterday I got a little done.
I finally made up the drive shafts, that should hold :)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150307_081801.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150307_081801.jpg.html)
Only kidding, I've sent those off to be made properly, and I'm hoping I should get them back in 3 weeks.
Then I faffed on for quite a while with the Boost plumbing, there are quite a few things that the pipe work has to go around, so its taking a while to get it right. Its go to weave its way between the engine mount, inner wing and the crank and alternator pulley, ensuring that it doesn't touch the drive shaft and suspension bits and has a little room to expand when the pressure increases inside.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150307_132042.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150307_132042.jpg.html)
Still a work in progress, but getting there.
More to come
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Keep at it.
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Mmm, I remember from my kit car days that the plumbing of air, cool and exhaust were terribly time consuming (and expensive!)
Keep the momentum going, it'll be great when it's done!
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Thanks Both, :) I'll keep at it :)
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I've made some more progress although this post is a little modest in the number of photographs. Sorry about that. I'll try and get back to old habits next time I'm in the garage.
Anyway, I've finally tackled the boost hoses, the outlet from the turbo, makes its way over the drive shaft, past the crank pulley between the alternator pulley and the inner wing and gets to the bottom of the intercooler, then the top hose is much simpler as can be seen here:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150312_214051.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150312_214051.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150312_214056.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150312_214056.jpg.html)
I've more or less got the main radiator hoses sorted (in my head anyway) so I should be able to get those fitted soon, and I've made a good start at altering the MR2 turbo exhaust silencer to meet the turbo outlet pipe. I'm hoping to get those two things finished over the next week.
More to come.
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Nice. Is that stainless mig welded?
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Indeed, I've got 304 wire and argon gas.
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Actually, I think its 316 wire :)
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Nice! Never tried stainless with the MIG. Looks like a good job you've done of it.
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I did all the stainless sockets into my stainless processor with stainless steel mig wire and pure argon.
It works quite well - a bit spattery but good enough for my needs and the welds are still as corrosion free as the processor and the fittings so must have been OK
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A little update. The exhaust is finished, i'm quite chuffed with how light it is now that its based on the turbo system.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150327_110340.jpg)
The new drive shafts have arrived and are now fitted:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150327_120857.jpg)
I had a very frustrating day on the car though, lots of time wasted trying to sort proof of the emgine change, and one of the CV joints arrived in bits!!! very frustrating.
More to come
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Keep at it, it is all coming together.
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Had a whole day on it today. I managed to get all the drive shaft and suspension bolts torqued up, although the bl***y TCA bolt took an hour to locate in the hole :(
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150407_201801.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150407_201801.jpg.html)
I took the EGR blank off and cleaned it up. It is much more visible than I thought it was going to be, so I've ground it back a tad.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150407_173113.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150407_173113.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150407_173819.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150407_173819.jpg.html)
Got all the bits of pipe and joiner sections together and connected up the main coolant hoses to the radiator (still got to connect up the heater hoses and mount the tank).
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150407_201716.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150407_201716.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150407_201730.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150407_201730.jpg.html)
Got the last under-tray mounted (although mainly with cable ties).
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150407_201739.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150407_201739.jpg.html)
And finally had a scratch around with the wire brush and applied a good coating of stone chip under the arches.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150407_201708.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150407_201708.jpg.html)
Just the brakes and clutch to bleed and it can go back on its wheels with all the remaining jobs to be done from above :) :)
More to come :)
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Closer and closer. How long till mot?
How's the brewing going and what news on the A3?
Ps have you got the geat linkage working yet?
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That's looking great, really coming together - thanks for keeping posting updates, I do love seeing projects like this! :) (I think it's part envy that I'm not doing it, and part relief that I'm not doing it, if that makes sense?)
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(I think it's part envy that I'm not doing it, and part relief that I'm not doing it, if that makes sense?)
Makes total sense, know exactly what you mean.
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I keep saying the same answer to that, but I think a couple of months. It could be done over a three day weekend with some help, but I don't have the luxury of time at the moment.
Brewing going well. Still enjoying it too :) I though I would have grown tired of it by now, but I still enjoy trying new things to make it faster :)
I've not attempted the gear linkage yet. I'm kind of working my way up the car at the moment. I should soon have it back on its wheels and then I'll start in the engine bay (coolant tank, heater hoses, gear linkage, air-box, and gear linkage).
Thanks Tony, :) I know exactly what you mean. It is so satisfying to do, but it can be such a pain in the arse. I don't get a great deal of pleasure from the dirty jobs (brakes and bushes) but they inevitably come up the most frequently!
Luckily this project has been quite light on those sort of jobs (so far).
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I've been busy with lots of other car related stuff, so haven't had any time on the MR2 for a while. But this weekend I did get some done, and with some help too :) (cheers Matt)
The exhaust is fitted, I've bled the brakes and clutch, starred for hours at the gear linkage, finished the coolant hoses (just the expansion tank to go now), trimmed the subframe where the driveshaft was looking a little close and even found a way to connect the Toyota air box to the TDI MAF sensor (not yet fitted but I know how :) )
I've done away with all the resonance chambers (turbo means far less pulsing in the inlet pipe). No need for all these:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20057.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20057.jpg.html)
Found a new cold air feed for the filter housing :) (without the massive resonance chamber):
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20056.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20056.jpg.html)
And I even managed to find the air box mount that I had previously thrown away :)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20055.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20055.jpg.html)
Then to top it all off, I got the diesel filter mounted and managed to start it for the first time with the exhaust on :) The video isn't very informative but the cut down long story is that the exhaust is very quiet :) but the engine is very loud!!! (I think I'm going to need to sound deadening under the engine cover)
https://www.youtube.com/watch?v=0Ke2LAJtPCc&feature=youtu.be
The first start is with an empty filter so it runs out of diesel pretty quick, second is after we'd primed the filter.
More to come
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I've had a very productive morning on the MR2 although my success has been accompanied by some new problems to solve. The fuel lines are all in now and the engine runs with the simple connecting of the battery and turning of the key :)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150426_113436.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150426_113436.jpg.html)
The vacuum feed to the brake servo is now connected up.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150426_113515.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150426_113515.jpg.html)
And the expansion tank is finally mounted and I've filled the system with coolant and bled it, although its not got fully hot yet, so there might be more bubbles to remove.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150426_113454.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150426_113454.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150426_113502.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150426_113502.jpg.html)
There are however a couple of issues. The coil light flashes after a minute or so of running, I'm not sure really what that means. And more concerning, it smokes! a lot! blue smoke, I think its unburnt fuel.
I messed around a little with the timing before the engine went in, I advanced it knowing that this can be a god idea with Bio, This morning I retarded it again to see if it cured the smoke. It made lots less combustion noise, but still smoked plenty. I thought this might just be down to it being on bio, but that can't be right, my 106 doesn't smoke at all. It could be that an injector or two is contaminated? I did run it a couple of times without a filter1 :(
Any ideas welcome? I've love to hear what you think about the smoke or the flashing coil light?
More to come
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What do you call the coil light? The orange coloured light on the dash, with a coil shape in it?
Is that the glowplug light. Just a bit of a glitch in the matrix somewhere? Wire shorting, or the glow plugs coming on, for some reason?
Was the engine ever on it's side? Could be a bit of oil got into the bores, and needs time to burn off, or a hydraulic lifter gone a bit dry. and not quite opening the valves properly.
I wouldn't get unduly concerned about it just yet. If it's still doing it after a good thrashing, then it's time to look into it.
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Being a total amateur at computerised cars I've still not managed to get VAGcom working on our Golf, but it too had a flashing glow plug light. The fault was read by a garage as two blown rear bulbs! Did I feel even more stupid than normal? However, they took pity on me and just charged for the bulbs.
Out to dinner last night with a friend who runs one of these Audi estates on steroids. He had the same warning and that turned out to be low oil level.
So, from my limited experience the light is probably only a minor fault and if you're lucky or smart enough to make VAGcom work, I'm sure you find out what it is.
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Cool, Right you are then, I'll give it a good thrashing to the MOT station and hope the MOT man has a reduced vision and smell that day :)
Hopefully I can borrow VAG Com off a friend of mine again :)
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Yeah, I mean glow plug when I wrote coil :)
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The glowplug light flashing is indication that the ecu has detected a fault somewhere, basically it is the fault warning.
You really need VAGCOM to scan it for codes and see what is wrong.
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From my years of playing with diesels, boats and cars,
blue smoke = engine oil burning
White/Grey/blueish = unburnt diesel (timing or injectors)
Black or black deposit on the rear = insufficeint air (badly coked valves or/and air filter/inlet manifold)
Any one of the above or a combination of.
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From my years of playing with diesels, boats and cars,
blue smoke = engine oil burning
White/Grey/blueish = unburnt diesel (timing or injectors)
Black or black deposit on the rear = insufficeint air (badly coked valves or/and air filter/inlet manifold)
Any one of the above or a combination of.
....and LOADS of smoke - The bloody thing is on fire. ;)
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You are welcome to vagcom again.
The coil light can flash with any fault on the break light circuit especially the break light switch. Have you connected one up yet?
Timing is set with vag com to get it accurate it would be worth setting it when you borrow.
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OOOOo I didn't know you could set the timing with VAGCom That would be helpful.
Thats a little annoying if it's a brake circuit thing, I thought I was pretty thorough keeping all that stuff so I could use the cruise control. I guess VAGCom will reveal all.
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Have a look at this
http://www.ross-tech.com/vag-scope/TDIGraph.html The video at the bottom shows all.
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Come back from holiday to some new pictures of progress, harrah! :)
Since the engine hasn't been used for a while, don't panic just yet, it may just need a good run. The Largo I'm currently using sat on the drive for months, and on starting ran really lumping, jumping engine, smoked out the neighbourhood, when revved was really rough. But after a good blast back to nice and clean and smooth. :)
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Wife was watching a program about a bag lady playing at being a detective last night, so I had a browse around Youtube and came up with one on building a 4x4 mini.
https://www.youtube.com/watch?v=7hCPODjJO7s
There's a whole series of 9 videos and they've only just finished the body and fitting major components, took a long time to watch them all (but way better than bag lady). There's some wonderful sheet metal work shown and the two guys approach things in an amusingly light hearted manner ... makes good viewing.
All rather reminiscent of what you're doing. They too keep their work space annoyingly clean!
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Was said bag lady the one with the LR ?
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Was said bag lady the one with the LR ?
I hope you're not referring to Felicity, she's a real babe.
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Wife was watching a program about a bag lady playing at being a detective last night, so I had a browse around Youtube and came up with one on building a 4x4 mini.
https://www.youtube.com/watch?v=7hCPODjJO7s
There's a whole series of 9 videos and they've only just finished the body and fitting major components, took a long time to watch them all (but way better than bag lady). There's some wonderful sheet metal work shown and the two guys approach things in an amusingly light hearted manner ... makes good viewing.
All rather reminiscent of what you're doing. They too keep their work space annoyingly clean!
Well that took care of my nights entertainment.
They're nutters, but very clever nutters.
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I've been watching project blinky for a while..... on the edge of my seat waiting for the next episode :-o
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I've been watching project blinky for a while..... on the edge of my seat waiting for the next episode :-o
gisa heads up when the next one is posted.
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I've made a bit of progress recently, I had a good day on it today.
The air box is in with a new filter:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150428_175216_2.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150428_175216_2.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150428_175256_5.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150428_175256_5.jpg.html)
And connected up via the MAF sensor. That's the Toyota air box and VAG MAF sensor.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150428_202929_6.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150428_202929_6.jpg.html)
And this morning I got round to joining the VAG gear linkage cables with the MR2 gear linkage cables.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150503_085417.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150503_085417.jpg.html)
It's all covered and sealed now too. I few teething problems with plastic melting as I welded :) but nothing too difficult to sort. Its by no means perfect, the Toyota gear stick was designed for only three rows of gears (with reverse being behind 5th), and now it has 4 rows (with revers being to the left of 1st gear). The travel of the cables is perfect, it's just takes a little practice to get the one you want (reverse, 1st, 3rd or 5th). I'll be fitting a quiet buzzer to warn when you've selected reverse. I'm pretty happy with it. I think it would be a dis-proportionate amount of work to make it a really slick gear change.
This meant I could drive the car around the driveway for the first time. It was running for about 3 hours, so I was able to test it a bit. Even so it only reached around 78 deg C. B***dy efficient diesels, I wasn't able to see if the cooling fan worked.
Here's a vid :)
https://www.youtube.com/watch?v=XR9Hp4XzfU8
I have found quite a few problems already though :(
There a clutch travel problem, well a lack of clutch travel. I thought I was getting away with it, push the pedal to the bottom and push it into reverse and there was no noise. But after a while it began to drag a little and grind into reverse gear. I'll try bleeding it again, but I might have to look into an alternative diameter master (Toyota) or slave (VW). I hope there is something that will fit.
Next, when I really loaded up the alternator, lights, fan, heated rear window, I think the belt area began to smoke, I'm not certain as there was a breeze, but I need to look into this a little further.
Mice have eaten part of the boot seal so I'll need to get another.
And there is a clunk when moving off in a different direction (forwards to reverse or vice versa), I think the third engine mount need looking at. As I was leaving I noticed that the exhaust flexi joint coming from the turbo elbow did not look "relaxed" as it did when I first made and fitted it, it seemed to be at a funny angle (not haha funny either!) So I think I might need to re-make or add too the third engine mount.
These fairly major issues put a bit of a downer on things this afternoon, having thought it was pretty much ready for MOT in the morning.
Oh well.
More to come
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Good going there, even with the few issues you have identified, it must have felt great to drive it out of the garage
There is a serious amount of turbo whistle going on, even at idle. I take it that the Toyota rear box does not offer a great deal of silencing
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Not bad at all. Looking forward to a trip in it.
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Thanks both :)
Yeah it does whistle a bit, i absolutely love it!!!! those giant american army lorries seem to be all turbo noise, i love that delayed drop in pitch long after the engine has settles at idle, too cool!
the exhaust is an MR2 turbo exhaust (muxh lighter than the NA exhaust that the car came with). It remains to seen how it sounds in the cabin at speed. i'm hopeful though, the engine noise drowns out the exhaust noise.
Dick, you'd be more than welcome to a ride or even a drive if you like.
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Proper movement, that is so cool, good work - not far to go now! :)
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I love the howl of a turbo. Looks like the dog does too.
I used to drive a tractor that howled like that. Opening her out up a hill, with a heavy trailer behind, the noise would make my hair stand on end.
After driving it all day, when I went to bed a night, I could still hear the turbo howling in my ears. The moment I dropped off to sleep, the howling would stop, and I'd wake up startled, wondering why the engine had stopped.......
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Opening her out up a hill, with a heavy trailer behind, the noise would make my hair stand on end.
I get that when loading up a marine diesel while standing next to it. It's an awesome feeling of power.
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with those big marine diesels it could be that the hair standing on end is actually the turbos trying to suck your head into them :)
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I've had a couple of evenings on the car this week, and although a lot of it was spent looking and thinking, I feel I've made some good progress towards solving the issues found when driving around.
I think I've found a clutch master from a Toyota 4Runner/Hilux is the same and the MR2 cylinder but larger diameter. This should solve the clutch travel issue without a minimum of fuss (fingers crossed). The MR2 cylinder is 5/8 and this would be 3/4, a 20% increase in diameter, but more importantly a 40% ish increase in piston area! That's quite a lot! Watch this space.
The exhaust is off again (only a 5 bolt job :) ) and I'm hoping that the flexi will bend back into shape. The damage to the flexi was caused by the third engine mount failure when giving it some stick in 1st gear. The torque at the wheels (and therefore the torque needed to hold the engine in place) is massive in first gear. As a ball park figure (I've not looked it up for this gearbox) first is generally 3:1 and final drive is around that too, so you can multiply engine torque by 9!!! when in first gear, and that's the torque that the engine mount has to withstand to stop the engine spinning int he engine bay.
Anyway... I've straightened the broken engine mount, used much thicker steel for the mounting points to the engine, and added more steel to the structure:
Going form this:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20035.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20035.jpg.html)
To this:
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150506_210300_1.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150506_210300_1.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150506_210310.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150506_210310.jpg.html)
But this is just the first part of the plan. I'm going to use some the position of the original mount, underneath the gearbox and make another section to join up with the bit pictured above. Strength in triangles.
More to come
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Keep at it. BTW did you get my email re oil?
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A small update this evening. I've bent the exhaust back into shape and the 'uprated' engine mount is complete, it should take a little more punishment this one. You can see as well as strengthening the original section, there is now an additional section that extends to the bottom of the gearbox, its a little heavy but I'm sure its much stronger now :)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150513_193623.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150513_193623.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150513_193611.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150513_193611.jpg.html)
I took it for a fairly thorough trashing up and down the drive, plenty of clutch dumping and other such fun and it seems to be taking the punishment.
I left all the electrics on too and the alternator/belt is no longer smoking/steaming so I'm putting that down to some coolant steaming off as it warmed up.
Just the clutch to tackle now and a few small tidy up jobs. Its really getting there. :)
More to come
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:D looks up to the job.
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what a project - ive got this engine in a skoda Octavia and am pushing 160bhp - so its quite tuneable!
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Too cool! i really want to tune it to around that figure, i feel that would finish it off nicely especially as it doesn't have to cost MPG, but saving money and being sensible have stopped me for now. One day i will
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Once it is on the road I give it 8 weeks till tuning starts!
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Hehe yes totally agree ;D
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I have a plug and play tuning box for this engine somewhere in the garage
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Let hope you're right :) :) There is a very good chance I won't be able to help myself :)
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Just stick a variable resistor between pins 2-3 of the ip plug.
Just put a 500 ohms resistor in series so you can't go to low.
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What do those pins signal/control?
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What do those pins signal/control?
It fools the ecu into thinking the engine is colder than it is and chucks more fuel in
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Right. I think we discussed this before on VOD - I've done similar on the Largo, on the fuel temp sensor that's part of the IP, but the other way around (signal the fuel is hotter, the ECU compensates for extra leakage past the high pressure plunger by injecting more).
All good fun :)
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I seem to remember that you can tell the ecu to inject more, or less, in one of the blocks using vag com, not done it though.
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Making Bio this weekend was a right faff, it took ages! But when that was all done, I did a little more on the MR2.
I finally got round to timing the engine properly following the cam belt change. This was only to get the cam timing right, I've still got to get the injection pump timing done with VAG-com.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150525_120035.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150525_120035.jpg.html)
Then popped everything back together, put the cross brace in, and the edge covers.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150525_140313.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150525_140313.jpg.html)
Then finally the engine cover.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150525_161253.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150525_161253.jpg.html)
Then it was ready for a wash. At this point I realised how late it was and packed up :(
Before the MOT I've still got to get a couple of slow punctures fixed, and the injection timing right, then give it a good clean and polish.
There is a bigger set of wheels and tires to go on to get the gearing correct for the speedo and bring the revs down a touch, but I thought it worth giving it a try first.
Close now :) :) :) :)
More to come
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Toyota looking good when is it planned for MOT?
What was the prob with the bio?
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Good luck with the MOT, with all your hard work I'm sure it'll be ok.
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Fingers crossed for the MOT. The car is looking awesome :)
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Thanks all :) MOT won't be for a while yet I'm afraid (even though the car is ready).
I guess you know about this, or is it just me?... If you don't put enough in the first stage it doesn't separate very well. I end up with dark bio coming out (a mix of glyc and bio), if I put a little more meth oxide in then the glyc falls out really quickly. Well on this occasion I hadn't put enough in the first stage, so it ended up being a three stager! The my second filter housing cracked, it all just ended up taking ages.
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That's the fun of bio.
Just when you think you've cracked it, it throws you a curved ball or two.
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That's the fun of bio.
Just when you think you've cracked it, it throws you a curved ball or two.
Usually when you least want the problems, I am sure it knows the most effective time to make us sweat. Just think of the saving and, for me, that usually smooths out the anguish.
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I guess that's what makes an experienced brewer, recognising how to correct every problem that can occur along the way?
Sounds like you figured that one out on your own though :)
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Oooo, Nice to be described as an experienced brewer, I think I've got a lot to learn though :)
I still feel very smug about the saving I'm making. to travel so fast on someone elses waste product is awesome :)
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I doubt any of us "experienced brewer's" think we know it all, well maybe one but we all know who that is.
Anyway what I'm trying to say is you never stop learning in this game.
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Its amazing how long I've been telling people that "it's ready for MOT", yet I've spent another day working on it :)
I borrow VAG-Com from Dick, Many thanks Dick. I timed the injection pump this morning. Got it well within the limits, but on the advanced side (good for Bio).
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150531_100053.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150531_100053.jpg.html)
Checked on the error codes and had a good go at trying to stop the heater light from flashing (to no avail :( ). The EGR and throttle valve fault I'm not bothered about, they're not causing the heater light to flash. The ABS fault is inevitable as the ABS is still in the Seat Toledo (and doesn't work on wireless) but the brake implausibility thing is very annoying. I don't think I'll be able to fix it really so I'll get the black tape out and cover it up :)
I also activated the cruise control :) and am looking forward to trying that.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150531_100446.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150531_100446.jpg.html)
Found that the flexi joint in the exhaust is leaking oil, this is annoying firstly because I thought I'd got away with it, but it looks like I'll have to buy another one, but more to the point what the hell is oil doing in the exhaust!!!!! I guess the turbo might be tired, or perhaps this is normal??? (it has been idling for about 4 hours) After the injection timing didn't cure the smoke I tried ragging the hell out of it up and down the drive to get it nice and hot and it did stop smoking :) :) :) I'll have to see about the turbo when its on the road (watch for smoke and oil consumption).
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150531_100509.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150531_100509.jpg.html)
I vacuum'd, cleaned and polished the paintwork with G10 finishing compound and normal car polish for hours to get rid of these very annoying stains, they did not want to shift!
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150531_125306.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150531_125306.jpg.html)
The polishing is by no means finished, but here is a teaser :)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150531_142844.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150531_142844.jpg.html)
More to come
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Very good. That break peddle problem is the break light switch. You should be able to fix it by just putting a switch on the appropriate pins. What it recognises I have no idea as, presumably, when the peddle is up and switch is off there is no continuity. Perhaps it checks the resistance of the two break light bulbs as I believe it is also activated by a failed bulb, if this is the case an appropriate resistor may do it?
Body looks well from the front now, you must be pleased.
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Ooh, shiny :)
Who knows with oil in the exhaust, it's been sat for ages. I wouldn't worry unduely unless that continues after it has been driven around properly for a bit and still does it. Give them turbo seals a chance to behave themselves :)
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I have a spare turbo I have reconed you can try once it is on the road if the problem persists. Though it could be a good excuse to upgrade?
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Thanks both :)
The pedal thing is a tricky one. It seems to work like this......
Brake pedal switch has 4 mins (2 switches, they are separate) and the clutch switch has 2 pins. There is a loop that goes from 12v to the ECU via the clutch switch then the brakes switch. If the pedals are left un-pushed this feeds to the ECU stays 12v. When either pedal is pushed it opens one of the switches and the ECU loses the 12v signal. I assume, this is for cancelling the cruise control.
The other switch on the brake is for the lights. When the pedal is left alone it is off, when you push it the switch closes and 12v goes to the lights.
There are a lots of theories going through my head about what could be causing it. I've cut through one of the wires going to the brake light switch, so when either pedal is pushed the ECU only sees a cruise cancel signal, just as it would when the clutch is pushed.
I reset the fault code and the light came back on :( :( :(
I think Dick is right and its just a bulb failure thing.
Black tape over the flashing light will cure it.
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Right then, a very busy month at work is over, I have booked the MOT for Saturday, then off into Whales camping :) :)
if it fails then we're in the pug 106 :( no pressure then!
After literally months of considering the options (from time to time), the wheels are now shod in 205 50 16, and 225 50 16 at the rear. All four are on Honda accord 16" 7J wheels.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150708_072345.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150708_072345.jpg.html)
The PCD is the same as the Toyota but the offset and center bore are different. I needed a 10mm spacer to put the wheels in the right place. I went with 20mm ish on the rear though as the wheels did used to look very "inboard". I went with hubcentric on the rear as 20mm is a little long to be relying on the studs for location. This meant I needed new longer wheel studs. 63mm was the longest I could get. I shortened one set by 6mm for the front and left the rears are 63mm long.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150708_085053.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150708_085053.jpg.html)
I used a hammer to knock out the old-uns, and a Toyota wheel nut in a socket top pull the new studs in.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150708_095047.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150708_095047.jpg.html)
Unfortunately I snapped one of the studs :( so I'm hoping a replacement arrives before Saturday.
Then the brakes were put back on and the spacer fitted.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150708_095525.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150708_095525.jpg.html)
Fronts done, just the rears to go (the front had just been jacked up at this point so is a little high).
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/IMG-20150708-WA0012.jpeg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/IMG-20150708-WA0012.jpeg.html)
All done! and once again the dog features in the photo :) The reason for changing the wheels was to get the right overall diameter, to give the diesel engine the long gears it had in the Toledo, this means the speedo will read correctly and engine won't be revving to much on the motorway, it is a diesel after all. I didn't want the car to look too bling, slammed on 24" wheels :) but I admit I wanted it to look a little smarter than it does on those 14" Toyota wheels. So I think 16" OEM Honda was a good compromise.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150708_165817.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150708_165817.jpg.html)
I've still got to replace that busted stud on Saturday morning, try and adjust the rear tracking slightly and give it a quick wash then its fingers crossed that a good thrashing and a tank of real diesel cleans up the exhaust fumes :) oh and hopefully nothing else is wrong :)
More to come :)
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I'll cross me fingers for ya on Saturday Loz, mind you a fail might be better than having teething probs whilst on ya hols
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Looking very good, as above fingers crossed for the MOT.
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Loz,You've made a very nice job of that, I'm impressed.
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You want a tank of bio for the MOT emissions will be lower on bio
than diesel.
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Thanks all, I'll keep you posted :)
Oakwoodtv,
The car is old enough for a "visual check" only. The Toledo drove up from Exeter without smoking at all, then I removed the engine put it in the MR2, changed the cambelt (and timed it fully and correctly), and ran it on bio.
I'll be working through a list of things to try and see why it smokes. The first and most obvious is to try normal diesel as I know it ran ok before. Of course I'm hoping its not that as I fully intend to run it on bio. But if it smokes less for the MOT then :)
Next I'll see if an injector is blocked/dripping, then perhaps the turbo seals have failed etc.
But for now its the easy stuff, a thrashing to the MOT station and a tank of diesel.
In usual Loz fashion I'm altering two things here in a non scientific way, but I just want the best chance of getting it through the MOT, I'll do science later :)
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The smoke cleared on the way to the MOT station :) i think it must have been oil in the exhaust (bought from ebay). The brakes cleaned up and passed ok and i have had an absolutely awesome day driving through Wales with her indoors, in Mr Two :) we are now canping ready for more MR2 TDI fun tomorrow :)
More to come
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Great news on the MOT, enjoy your holes.
I bet the MR2 is fun around the Welsh lanes.
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Are you aware that MR2 in french sounds Veeeeerrrrry much like shit, well their word for it.
I had to come back this post to congratulate you on completing a fantastic conversion, I've watch with interest from day one.
Bloody brilliant job.
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Congrats. What is the next motor related project?
Drop it by when you are passing looking forward to a ride in it. It will be interesting to know what the fuel consumption is.
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Brilliant, wish I had half your determination.
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Tidy. Not a bad weekend for a spin around Welshire, either.
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Thanks again folks :) :) my head won’t fit through the door.
There are a number of things still to do (things that I knew about) and a number of new minor issues to solve, so I’ll keep checking in here. I’d like to take it to the drag strip just once and put it against a standard MR2 petrol (NA) I’d like to see how far off it is. And of course, I’ll be doing some lorry chasing, normal driving, and crazy driving, and will report on the MPG figures.
I’ll write a little about the weekend for anyone interested.
I got up early and changed the last wheel stud, no dramas there really, got the rear tracking in spec, (front is already good) and gave it a clean. Then off to the MOT station. By the time I had got to the petrol station it was smoking pretty badly, I was in two minds about turning back, there was no way it would pass! I stuck with it, just in case it was the bio diesel.
It only took about 20L of fuel before it was full? Then I remembered I put load of bio in to see if the fuel gauge worked. I set off up the long hill through Bromyard and it was smoking like mad. Everyone was looking at me for all the wrong reasons it was thick blue smoke! I’d lost hope by this point, I was thinking of new injectors and turbo etc. My thinking was, I’m on the road and legal for now, lets just enjoy it for a few mins. I thrashed the hell out of it for a few more miles and as I approached the MOT station the smoke began to the reduce, so I went on a mile or two. By the time I got back to the garage, there was no visible smoke at all, even under full throttle.
I’m pretty sure now that this was as a result of the “MR2 turbo” exhaust I had bought off ebay, I imagine the previous owner had failed a turbo and put lots of engine oil into the exhaust. I had now finished burning it all off.
Anyway 40 mins later and a few comments from the MOT man, I was good to go. Went back for the missus and the tent and headed for Wales.
We went to the dams at Rhayader, then on to Aberystwyth via the really rather excellent “mountain road” or Elan Valley. Camped in Devils bridge and faffed around in Aber today, then home on the faster road, here are a few pics followed by my thoughts on the car.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20070.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20070.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20073a.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20073a.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20074a.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20074a.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/Picture%20075.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/Picture%20075.jpg.html)
This is an MR2 with a diesel engine! I can only take credit for engine transplant, everything else is standard. The handling can only be put down to the genius engineers from Japan. I knew this was the case and this is why I went with this car. I really love the way this thing drives, I would say that it doesn’t have the feedback and truly instant steering feel of the MX5, but it is very close. The most important thing here is the lack of weight at the front. It changes direction so dam quickly.
It “quite nice” at normal traffic speeds and there are no nasty traits what-so-ever, but when you press on a bit and push it through the corners that’s when it really shows its true colours and gives a feeling of confidence as if to say “is that all you’ve got!”. It is very precise and gives the feeling that there is plenty more grip on tap. It’s really very good fun. Having the roof off is fantastic, and once again really good fun, the noise can perhaps get a little tiring after a couple of hours.
Back to the engine. With the windows closed and the roof on, there is more noise than the petrol engine gives but not by a huge amount, its quietest between 1400 and 2500rpm which is spot on for everyday driving. There is plenty of power and torque for overtaking. It remains to be seem how fast it is against the standard car. However for normal everyday driving, the kind that you do on your way to work, I would argue that this is quicker. (unless you are someone who actually red-line’s it all the time).
I have given the “power booster” ebay special a go now and it seems to make a difference although the “35hp” claim might be a little generous. Watch this space for more info on that.
I did manage to hold back and see what MPG it would do this evening. I did 13miles and the destination was at a slightly lower altitude than the start point so its by no means gospel. But the figure of 78 mpg was on the dash when I arrived. The wheels are the correct diameter for the speedo to read correctly so it looks promising. I’ll be doing lots of actual measurements soon to get some real numbers.
You have my respect if you have managed to read this far, I think I would have put most people to sleep by now. I’ll be back, there is at least another couple of months of work to get it just right, but its been a good weekend for Mr Two TDI.
More to come
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Loz came round last night to show me the car and take me out. I can report that it is as good as it looks and goes like stink. The pull from the diesel is very impressive and does not, in my mind, in any way reduce the car from being a sports car.
I can only say well done, I want one and if you get tired of it give me first refusal!
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Outstanding. Looks like a lovely day at Aberystwyth. Sea is a lovely colour.
That road between Elan Valley and Aberystwyth, there are some old ruins on the right hand side, I think the name of the place is Cwm Ystwyth. Huge layby on the left, going down the the river, and the ruins against the hill side.
That's an old lead mine. Well worth a poke about for 20 minutes.
(I need a car so bad. Can't face the thought of taking a 3.5 tonne transit across that Elan Valley road again.....)
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Looks great lozzzzzz!
Last time I charged across Wales was in the Largo, my passengers were definitely a bit worse for wear after that, must be delightful in the MR2 :)
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Thanks all :) :) You're very kind Dick, someone at work wants first refusal too :) I'll be hanging on to it for a while yet :)
I know the bit you mean greasemonkey, I have stopped there before :) I wanted to this time, but it was raining when her and I went past on saturday :)
I still haven't brimmed it for a proper calculated MPG yet, but this was the figure on the dash when I arrived home from work today. A 45 mile journey, the majority of which is motorway, but 1/3 of it is A roads, with some ques! (there was a bit of lorry chasing on the motorway mind :) )
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150713_170603.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150713_170603.jpg.html)
More to come.
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You get 4x the distance per litre that I get!
How's the turbo whistle now you get to properly open it up?
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You can just about make out the boost noise, the whistling can't be heard really. If you aee what mean?
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You get 4x the distance per litre that I get!
How's the turbo whistle now you get to properly open it up?
I get a smidge over that Tony (24mpg).
Loz, you must stop lorry chasing, it makes the rest of us look bad, plus that car is to be enjoyed not strangled on economy runs.
Get out a boot it around the twisty bits, like you stole it.
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awesome work and awesome build.
which engine code is it you have in there? Cause if its a asv or equivilent, i have a 170bhp kit for sale including a hybrid turbo, intercooler etc :)
Should go really well in that.
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awesome work and awesome build.
which engine code is it you have in there? Cause if its a asv or equivilent, i have a 170bhp kit for sale including a hybrid turbo, intercooler etc :)
Should go really well in that.
Go on Lozz you know it makes sense!!
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I did this with the pug, i just want to make a record of what it can do, then i'll testing the handling a bit instead of mpg :)
Its an AHF engine, will your stuff fit? What have you got?
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mine is off an asv engine - not sure if it will fit, but then you got this engine in an MR2! :) - you will have to check up on other forums perhaps, but its a hybrid turbo, injector nozzles, side mounted intercooler with alloy pipes and proper clamps, and the maps :)
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oh, and egr delete kit, and pd150 inlet manifold
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I've done a lot to the inlet, and I think I'd have to go roof mounted to fit a bigger intercooler, I think my only options are the turbo and injector nozzles.
I can't really afford to spent that money just yet although I'd very much like to.
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Well I've done well over 500 miles in Mr Two now and I'm falling in love with it. It really is exactly right! Fast, economical, loads of fun, and really quite tolerable on a long run. I love it (did I mention that).
I can now confidently say that I have accurately measured the MPG and compared it to the read out on the dial. Unfortunately the dials are a little optimistic, by 10% in fact. I was a little disappointed, however a 10% error means it was still able to do 80mpg on a long run behind a lorry. Still impressive I feel. The average for that tank of fuel was 70mpg, that's mostly motorway driving (slowly) but perhaps 1/3 of it was A roads. I've since tried driving it like a tool to see if the 10% error still stands in the region of 50mpg. I'll fill the car up again soon to test this.
The gauge suggests that the car can do 63mpg at a steady 70mph and this drops to 54mpg at 80mph (as I said I'll confirm these figures soon), this really makes me want to fit the 6 speed box. I don't know for sure if it'll bolt up to this engine and whether or not I would need new driveshafts again.
I think I can fairly safely confirm that its not as good as I previously suggested on MPG, but is certainly no worse a golf TDI.
Anyway, thats enough about MPG, at 30 to 35p/l fuel is cheap therefore motoring is very cheap! :)
In other news, I've now fitted a very lame stereo, soon to fit some speakers, nothing fancy, just normal stuff. I've messed about with and shortened the little gear lever on top of the gearbox (this has made a very small difference, it still needs a little adjustment) and I've cleaned up and "stone chipped" the rear arches and underside of the car. I feel happy that its weatherproof now :)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150716_181546.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150716_181546.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150716_192024.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150716_192024.jpg.html)
I can't get my head round how solid this car is underneath :)
To sum up, its friggin brilliant!! and I love it! :) :) oh and the front brake is binding a bit :(
More to come
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That's some serious MPG.
Is that stonechip stuff a one coat solution to corrosion, or would it be better put over, or under a coat of paint?
Is it available in brush on cans, or is it only spray?
I used to like underseal, but I've gone off it a bit, at least for really sound metal.
I don't have any spraying equipment. I should invest in an electric spray gun really, but I just need to get something under my transit pretty quick, and would rather spend the money on paint than kit, just at the moment.
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I think its overpaintable, you don't have to though. I bought the cans that attach to a paraffin air gun. You can get spray cans (aerosol cans) or you could buy the big cans I got and brush it on from them.
I used Waxoil for a bit, years ago, but its really c**p, it just washes off. This is awesome stuff and dries to a rubbery finish, very tough. I believe this one is zinc based too...?
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Ah, cheers for that. I might give it a go then. Might paint first with some thinned down paint to get into the fissures, then go for the stone chip. I was wondering if it was rubbery. That's what I was looking for really. Less liable to crack.
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indeed! Its good stuff!
I think its Dinotrol stonechip 447
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Oooo! That ain't cheap....... I can see it's ace for the arches, but I think I'm going to hesitate to do the whole of the underside of the cab with it, especially considering the age of the vehicle, and how sound it is. Probably overkill.
Might get a can just for the arches mind.
Anyhow, I've got to get my mega truck ramps welded up first, and have a good inspection. This weekend, with luck.
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to convert to 6 speed would be a big job, you need drive shafts, clutch, flywheel, starter motor and gear cables. the clutches are expensive for a 6 speed too
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to convert to 6 speed would be a big job, you need drive shafts, clutch, flywheel, starter motor and gear cables. the clutches are expensive for a 6 speed too
You don't know Lozzzz, big jobs on cars are normal for him!
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I'm not afraid of a big job myself :-) I fitted a ford 2.9v6 Granada engine into a lada niva 4x4 which involved cutting the floor out and remaking it.
Ive read through the thread and have no doubt he will be able to do it, I think I came across wrong when I said big job, its all relative I guess.
Another thing to note is the physical size difference of the 6 speed box compared to the 5 speed. the 6 is a two person lift to get it back into a car when changing the clutch, and a 5 is doable on your own. I do like the 6 speeds though, and the 6 speed clutch will handle around 300lb/ft of torque in standard form. However to spend the same amount of money on a 5 speed clutch you will be well into competition specs. For future reference if you do plan on tuning the ve tdi engine with a 5 speed in it, I've tuned pd engines with 220bhp and 350lb/ft of torque running through a g60 flywheel, and a vr6 clutch which ill all bolt right into the mr2 as it is now and does away with the dual mass flywheel 8)
with a set of .216 injector nozzles and a remap this engine would do around 150ish bhp, would make for a very fun car. Stick a pd150 turbo on there (you may need a new engine mount though depending how you have it setup) and some .260 nozzles and you should be seeing 170/180bhp quite reliably.
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He will be tweeking it. His scimitar is bonkers. We should start a book on when he does the first tweek!
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I've missed these recent post and not replied, how rude!!!
That's interesting to know about the complexity of the job. I have found next to no information about putting the 6 speed on the earlier engine anywhere on the interweb, I guess the PD is a good tunable motor so no one bothers. From your reply SimonAllen, I assume that it will at least fit bolt up to the AHF engine block? I've no doubt the 6 speed will improve MPG, particularly on the motorway, but with my Bio being 28.5p I have to think about how long it will take for the saving to pay for the conversion.
Thank you for your kind and encouraging comments Dick :) I have spent the last couple of weeks flicking from "I'll get a 6 speed" to "Its not worth it, stick with this" on a near continuous basis :) :) Watch this space.
I bet that Niva was good Simon, I've always thought the Essex engine into a series landy would be good, but the niva with the later engine would be way quicker :) I've read so much about tuning this 110 AHF engine and it just seems crazy how easy and cheap tuning it is, especially when compared to a petrol engine. I'm really trying to save money where ever I can at the moment so serious tuning will have to wait, but it great to know how much you can reliably get :) :)
(saving money....... perhaps I shouldn't have built and MR2 TDI and just stuck with the 106 :) :) )
Anyway as Dick say, I have been tweaking it a bit :) read the latest update. 69p tuning isn't bad right? :) :)
I've not written an update for a while and I've done a few bits over the weeks.
I've been driving in a much more normal way now (not lorry chasing). Like fury early on Sunday mornings :) and at least matching motorway traffic speeds on my long daily commute. The average figure over a few thousand miles has been 54.2mpg. I guess I was hoping for a little more but that has included a lot of of revving and "pressing on" so not too bad.
I've got a list of very small niggles that I've been working through and have recently tackled the one I considered to be the trickiest. The heater light was flashing on the dash board which suggests a the brake pedal switch problem and would not allow the cruise control to work. After much forum reading and head scratching I've finally stopped it and cleared the fault by connecting the MR2 brake lights through the TDI pedal switch. This means when the pedal is not pushed the ECU detects earth via the brake light bulbs and is now happy.
This means THE CRUISE CONTROL WORKS :) :) :) :) :) :) :) :) Very pleased :) :) :) I've yet to mount the switch properly but the tricky bit is done :)
I've fitted some speakers and a crappy radio for now, so it's been nice having the radio for the daily commute.
I've mounted some mini push switches for the MFA to work, it turns out it's still over estimating the MPG by 10% but all the other function are great.
I've had a play with the "tuning box" and found it's a 2K resistor (which expains why it didn't do much), this is way to much! so I've been messing about with a 69p 1k variable resistor and it seems to work all the way down to 500 ohms. It transforms the performance, in fact I would go as far as to say it makes the 110hp engine in the MR2 at least match the performance of the Fabia VRS which was my target for this car. I'd still like to drag race it and find out the difference with and without the resistor and it would be very interesting to get it on a rolling road and find out the numbers too.
I've "adjusted" the leverage ratio of the throttle pedal to accommodate the TDI throttle pot more suitably. The pedal required quite a bit of force to push and had very little travel. It's funny how much this has transformed the driving experience, I'm very pleased I pursued it and will be trying various things to improve the gear shift next :)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150909_195451.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150909_195451.jpg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150909_200319.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150909_200319.jpg.html)
I've now driven the car several thousand miles and I'm still besotted with it! Its a joy to drive. With current fuel prices at around 1.10p locally and my fuel being 28.5p, the car is doing a cost equivalent of 209mpg. Can't complain really :) :)
More to come
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After a frustrating morning (set about fixing the missus brakes only to find the locking wheel nut key was missing), I went and fetched Mr Two and had a go at improving the gear shift. On the way back in the MR2 something went wrong for the first time :( One of the gear change cables broke (at my weld). So I repaired and reinforced that then set about improving the gear shift feel.
I've just moved the point at which the gear change cable attached to the gear stick, and it has improved the feel infinitely, I had sort of resigned myself to the fact it would not be a particularly nice shift feel as it was a 'mish-mash' of two different OEMs parts and as the gearbox lever had a big counter-weight mounted on it (that's now gone). But it's lovely, sideways movement is ok, still a little tricky to find 1st and 2nd for a new driver, but forwards and backwards movement is fantastic! A really nice click into gear!
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150913_141432.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150913_141432.jpg.html)
It seems to take a long time cranking over before starting when the engine is up to temperature, from reading about a bit it seems others have had similar problems on the 110hp engines. I had thought that this might be something to do with the EGR and intake throttle solenoids being disconnected (it shows a fault in VAGCom). I connected them up again and they are now sat on the passenger seat clicking away :) I cleared the fault codes and warmed the car up with a spirited drive. I've only started it hot a few times, but 'fingers crossed' I think it is starting normally now. I might get a couple of resistors to replace the redundant solenoids and keep the ECU happy.
More to come
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It will never be finished, resign your self to it!!
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I feel that it might be approaching finished :)
Well you're right really, I guess what I end up doing (did with the scimitar) is to put somethings on a wish list, and some things on a to do list, and I can let myself call it finished when the to do list is complete.
For example I would like the wiring tucked away, the cruise switch to be neat and easy to use, all four speakers working well etc, it will be "finished" when these are done (and its getting close now). But serious tuning, rev 2 rear suspension, and a few other things will remain on the wish list for now, as I'm not flush with cash.
After spending several hours fixing the bio machine I finally got round to making some more adjustments to Mr Two. This one is to make the car a little more "get in and drive" when someone else uses it, rather than spending 10 minutes explaining the little nuances of the car.
I wanted the gearshift to work a little like the BMW I used to own. Push left for 1st and 2nd, push hard left for reverse. As it is, it can be difficult to decern between 1st and reverse. So I made this.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150916_201503.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150916_201503.jpg.html)
And welded it on to the base plate by the gear lever (note that when the gear lever is moved left or right, the lever in the left of the photo moves forwards and backwards).
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150916_202520.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150916_202520.jpg.html)
Then finally got round to reducing the diameter of the Toledo gear stick top, and gluing it into the MR2 gear nob.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150916_195036.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150916_195036.jpg.html)
The finaly test was to lend the car to the missus and see if she could find all the gears with no issues, and...... she can :) Although "it is a bit hard to get reverse"..... I can't b****y win!!! :)
More to come
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Hi folks its been a while, I've done about 12000 miles in Mr Two now and its going very well. I have recently done a few little jobs to try and get it up to scratch.
Firstly I've painted up and cut the holes in spare MR2 dash that someone kindly gave me :) That's now fitted and doesn't have a huge crack across it :)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/20150927_161020.jpg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/20150927_161020.jpg.html)
The sump plug seemed pretty loose last time I changed this oil, so this time I took it off and tapped an M15 thread in there and fitted an oversize plug. I cleaned it out too although I was very pleased to see how clean it was.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/IMG-20160116-WA0000.jpeg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/IMG-20160116-WA0000.jpeg.html)
It seems to be smoking a little when cold, all clear after a mile or less but idling from fresh cold there is a fair bit of blue smoke. In addition the VNT seems to be getting pretty clogged and producing over-boost limp mode (nearly all the time recently). I took the Turbo off and cleaned it up. I attacked the VNT with oven cleaner then a little time in the ultrasonic cleaner at work, its now totally free. I replace the turbo cartridge with a new one and checked the oil supply.
I also replaced the heaters for cold starting and took the injector nozzles off and ultrasonically cleaned them too.
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/IMG-20160116-WA0006_1.jpeg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/IMG-20160116-WA0006_1.jpeg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/IMG-20160116-WA0002.jpeg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/IMG-20160116-WA0002.jpeg.html)
(http://i97.photobucket.com/albums/l217/lozzzzzzz_2006/IMG-20160116-WA0004_3.jpeg) (http://s97.photobucket.com/user/lozzzzzzz_2006/media/IMG-20160116-WA0004_3.jpeg.html)
Finally got it all back together yesterday which was nice as my crappy 106 has given up and the Scimitar still waits patiently for Pre MOT prep in a few months.
Has it cured it.....
It seems not. I just went out to cold start it again and its still smoking away. Oh well, its got lots of new bits and works.
More to come.
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I had a similar cold start problem with a boat engine, turned out to be slightly retarded timing.
A quick reset and all was fine again.
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I could always try and look at the timing again but I did time it properly with VagCom before I got the car MOT'd (thanks Dick).
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You are welcome to vag com again. Are you winterising your bio? A splash of petrol might help while the injectors warm up.
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That's very kind Dick, I might take you up on the offer again to alter the IQ value, it seems to judder no idle while coasting (but not stationary). A little googling seems to reveal that altering the injection quantity can stop this :)
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Blue smoke, as you probably already know, is unburnt feul so a bit of advance beyond standard could be an advantage.
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Just had another thought, you say you cleaned the injectors but did you check and reset the crack off pressure of each one?
If the opening pressure is incorrect so will any static timing setting.
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I have a pop tester if you want to test them.
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I have the same engine in my Galaxy and FWIW it also has a slight blue smoke on idle from cold in the winter.
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I'll try the IQ change first then look at the timing again, then perhaps I should pull the injectors out again check the pop pressure if thats ok Dick :).
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I'll try the IQ change first then look at the timing again, then perhaps I should pull the injectors out again check the pop pressure if thats ok Dick :).
Don't forget spay pattern is more important than crack off pressure.
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Hi everybody. It's been a long time.
Mr Two has done a stirling job of carting me about. I've done 50k miles in it all bio powered :) unfortunately the slightly heavy clutch is beginnine to annoy my leg and i'm looming for an auto alternative (then i'm gunna electrify Mr Two with leaf parts :) )
One of my options is the audi 2.5 v6 engine. I believe it might be one of the last engines that I could put dirty bio in (b70-90). I don't want to have to make b100 really.
Does anyone have any experiance with the VAG 2.5 V6 engine on bio? Or any advive to offer?
Thanks in advance