Ben's Black Mk2 2.0 16v Project

[Judderi]

23/11/05

Last night i just got to the bosch centre in time with the injectors. I had an interesting discussion with him about the whole 2 litle conversion. It turns out they have a rolling road and will be able to check everything over for me and get the motor running perfect. He also seemed to know what he was talking about when it came to the LPG setup. Also their price is no different to my other local RR centre and ive used them before and was more than happy with the service. So its going there once its all back together.

Last night i spent a few more hours putting it all back together and cleaning parts. Here is my progress so far.

This shot shows the rear fixing bracket for the manifold and my special tool i used to make it fit. 

Then on was the intake boot and idle control valve and the 5th injector and the WUR fuel lines.

1 by one im cleaning the fuel lines which is a right pain but will be worth it in the end. More updates tomorow.

[Judderi]

25/11/05

Got the injectors back last nigh. They were all running fine, so have had a good clean and new seals where needed. So hopefully it will all be back up and running tonight. Fingers crossed! 

[Judderi]

29/11/05

Well well well..... Got it all back together and had problems starting. So i got some jump leads from a friend. Still no joy! Then a guy down the road came and started to help. Turns out the 1st plug was drenched. So cleaned that up and brum brum the engine started. But dont get y hopes up, cos it didnt keep running. It seems that the origional fault was still there. So much for my diagnosis!  Oh well, at least i got the polished manifolds on. So i rang a local ish Bosch centre who i had used before and was very impressed with and booked the motor in. So me and a mate towed the car in a snow blizard round country roads and a couple of dual carrige ways. Very very scary! 

Just got a call now from the garage and they have fixed the problems. Easy as that when you know how!  Turns out the air mass meter needed re-setting (didnt even know it had one) And the timing needed doing which i suspected was the case as its been pinking. Its also got a water leak on the LPG vaporiser but i think this is just a jubilee clip.

While its there i asked them to plonk it on the rollers and test the fueling side of things to make sure the k-jet system can cope with a 2 litre conversion. They will also be able to get me a long awaited bhp figure.

So at the mo i only have a few finished pics of the manifolds for you all to feast your eyes on. At least it looks good! 

Also this hose had collapsed so i replaced it with a propper elbow joint hose which was kindly donated by my kind neighbor who also said i can use his equipment anytime etc. Hey hey! He will never be able to get rid of me now!

I also replaced all the vacume hoses going to these little gizmos. I have no idea what they do like.

[Judderi]

01/12/05

Well i got it back last night and all is good in the world again. It runs very well and idles very nice for once in its life. Theres still a few odd jobs to do though. I need to sort out a coolant leak on one of the lpg vaporiser hozes. I also need to trim a vacume hose and fit it correctly. I need to swap my wheels for my winter set as my tires are illegal. And the battery could also do with a charge.

My starter motor is also very dodgy now. Its taken quite a hammering lately trying to get the motor started and i thinks its starting to give up. Hopefully it will just need a service.

So ive nicked some of them rubber gloves from the petrol station and hope to have it all done tonight ready to go to Oasis in the morning.

[Judderi]

6/12/05

Right back from my short break and have a little update. I crashed on the way home and wrote the car off.  Only Joking!  Nah all is good. I sorted the water leak which turned out just to be a crap jubilee clip not holding the hose propperly. Charged the battery and changed my wheels. It sits well low now its back on the 15's. Will get some pics for ya all after i wash it. Its absolutely caked in muck after my motorway journeys. Hopefully it will come back to its former shine after a good wash. But now it also seems that my fan has stopped working. I have no idea why so will put a post up in the mk2 section.

[Judderi]

12/12/05

Well i eventually gave the car a quick wash this weekend. I also sorted out my problem with my radiator fan not coming on and the engine overheating. Turns out it was just an air lock, or was it? All will be explained. But first a funny story. I normally run around on LPG which isnt exactly a performance fuel. So once in a while i get a real big urge to switch over onto petrol and give the car a real good thrashing. This happened to be while at my parents for tea and my dad asked me to go to the local shop for a bottle or 3 of lemonade and coke. The local shop is about 2 mile away. The engine was already warm from the journey to my parents so on came the petrol!  And bugger me that car is fast when it wants to be, i didnt really get proper traction till 3rd gear! And the noise it makes is quite frightening! Anyway i ended up having to go to three different shops all at warp speed cos no where had lemonade, i didnt mind though, was having great fun! Then things started to go wrong a little. Firstly it seems my radiator fan decided not to work again and i started overheating. Because of this extreme heat the motor started pinking real bad, which wasnt helped by the fact that i was running standard fuel and not optimax. Then i lost 5th gear for some bizare reason. All problems aint that bad really. I will check out the water again tonight and try and clear the air lock, which i would of had to do anyway cos i wanna take one of the matrix hozes off cos it feels like its blocked with gunk. 2 im gonna fill up with optimax next time i pass a shell garage. And then theres the 5th gear problem. Which in turn is another story.

Ive already got most of the replacement bushes for the gear linkages and a new cup and ball, so i thought now is obviously a good time to fit them. However the same night we went to see some friends and watch a video. They have 2 rabbits as house pets as she is alergic to cats and he doesent really like dogs. But everytime i go i start sneezing and my asthma starts making me wheeze. So i looked in my coat pocket for an inhaler and it wasnt there, so i thought it must be in the car. So when we left to come home i was looking around in the car and to my delight and amusement it had fallen into the gear gator on the right of the stick - hence the reason why i could not push the gear stick over to the right and select 5th!  DOH! i felt very daft but none the less a little relived.

Heres some pics i took just after washing the car. Im glad it turned out shiney again and is no longer a dull brown colour.

[Judderi]

14/12/05

Oh by the way. Since the starting problem when the garage re set the fueling and ignition timing my noisy tappets have silenced completely. I guess they wernt faulty after all. Which is nice.

The other night i made a quick start at soundproofing my doors. The door cards have been off for months and the sound proofing arrived ages ago so its about time i made a move. I used methalated spirits to clean the interior of the door which turned out not to be such a good idea as it leavs a bit of an oily residue behind. So i will have to do it all again. This time im gonna use an alcohol spray used to clean electrical components. I know for sure this stuff evaporates fully! I bought a roll of www.fatmat.co.uk its prety much identical except for the logo to dynamatt extreme only much cheaper. Not much to see really but you get the idea. Pics will follow when i get off my ass and finish it off. I could do with a heat gun and roller really. Will steal them from my parents house tonight if i can find them cos there on holiday and will never know. That seems to be the way ive inherited all my tools!  Gonna raid the freezer too cos im skint and cant afford food!

[Judderi]

28/12/05

Oooooo look at the pretty snow. And my angel eyes!  In real life the ring looks smaller and clearer. If only i knew how to use a camera!

[Judderi]

30/12/2005

Well with the extra cash i got over christmas ive decided to treat myself a little. Ive been planning on an in car pc for a few weeks now so decided to take the plunge and buy the most expensive part 1st - the touch screen. I opted for this little beauty on good old fea bay. Im planning on mounting it flush in the lower centre console where the ash tray and leccy windows are. I will relocate the window switches to the top part of the dash under the hazard/rear screen/fog lights.

http://cgi.ebay.co.uk/Lilliput-7-Touch-Screen-XGA-VGA-TFT-Car-Monitor-2005_W0QQitemZ5847349880QQcategoryZ14946QQtcZphotoQQcmdZViewItem


I also purchased a new temperature switch to hopefully fix my non operating radiator fan and a nice new blue coolant bottle cap cos ive heard they are better than the origionals. Ive also splashed out on these beautys from Missing Linkz to sort out my bus style gear change.

Have a look at the following link if your having dodgy gear changes. Its a good old read and can explain allot.

http://www.4crawler.com/Diesel/ForSale/ShiftLinkage.shtml#FAQ22

[Judderi]

04/01/06

My screen arrived! Its exactly what i wanted really. Havent trial fitted it yet but i will make it fit no matter what! The quality is really good, most impressed i am!

I just need the pc now