Busy week so far... been very hot and my sorry excuse of an office based a55 is certianly not used to this kind of physical exertion lol
Starting where I left off... pinned up the N75, MAP and IAT sensor into the ECU plug... the plug typically has the spare pins already there for use.. they are a bit like a scotchlock in operation so I soldered the wires instead...
Fitted the loom into the car...
The VR's 'after run' pump is on the block and appears to use the same output as the 1.8t's one... the wire gauge for the S3 looked a little smaller than the VR so I unpinned the S3 wire and repinned a thicker gauge wire for the VR...
As I couldn't find the right terminal sets for this plug short of buying a new plug I depinned the VR side and used a single Tyco AMP connector to join the pump wires... I also ran the original wire that goes to the S3's pump plug on the other side of the engine bay so that I can potentially use it to power the S3's original pump for the turbo... I will use a relay though as not sure running two pumps on that output is a particularly good idea
On the subject of the turbo... I test fitted the manifold and turbo to get an idea of room and challenges that may present themselves...
Actually quite a bit of room considering... I may look at moving the comp housing away from the manifold by rotating it back or either extending the outlet so the silicon joiner can be a little further from the heat or maybe look at using those alloy vband jobbers for boost pipes...
The turbo sits more in the middle on this main than my previous 20v fitment which is not the best but with a couple of tweaks I should be able to reuse my old intake pipework...
Room for the downpipe looks ok but will need to angle it away from the bulkhead a bit and maybe use 1D bends... I didn't think at the time to grab some and try but pretty confident a downpipe will be easy enough to sort out... I made a 3.5" DP for a K04 in an S3 so I can easily bang this one out
Lastly I checked the wastegate... in this case a Turbosmart WG45 gen5.... the mani is designed for a 2 bolt 38mm gate but as I will be using low boost (relatively) then I want the control the larger WG will give me so will need to adapt it all to fit... I have an adaptor enroute so will post pics later...
The gate is tight... the heatshielding will need a little adjustment to give a little more room... I am also considering machining the WG mount on the mani to angle it more into the centre which will give more room fitment wise...
Removed all that turbo gubbins (sadly) and fitted the OE manifolds and downpipe instead... actually not too bad to do but will do a spanner check once the car is on a ramp anyway..
At this point I connected the ECU and then the battery.... nothing caught fire... and no magic smoke was released... winning
I went a checked Ignitron to make sure it could see all the engine sensors and stuff... ran through the output tests and everything was going well until I went to check the injectors... they did not turn on... b*gger!
Called it a day and took the inlet mani home so I could make (old skool style) a gasket from gasket material... while catching up with Jack Frags and Linus Tech Tips on Youtube...
Been a while since I have to do that lol... there isn't really a gasket available for this manifold... well... there is but its 35 bucks + about 40 bucks shipping!!!
New day... Today my intent was to get the engine started... I was still waiting on Parcel Farce to deliver my radiator hoses (couldn't find Badger 5!!) so I cracked on with everything needed to turn the engine over...
Filled the engine with oil, filled the gearbox with oil filled the radiator with... ah... no... hoses still not arrived as they couldn't find Badger 5... so called the depot and told them how to find it...
In the mean time I had worked out why the injectors didn't work... the fuel pump relay needs to be on... so ticked that box and ran the injector output tests... all working... phew!...
I plumbed the fuel filter in (the old one for now) and plugged the fuel pumps back in and fitted the inlet manifold...
Ignitron has a feature that over a certain pedal percentage it will go into a flush mode where it will turn over with injectors and ignition disabled... this is only while cranking and is useful for first start scenarios or arguably an oil change to get the oil circulated...
This went well... nothing leaked, the engine turned over easily with no worrying noises.... soooooooo....
.....yay!
Its fine to run the engine for a very short time with no coolant but I wouldn't make a habit of it... it was enough to get the engine fired up... it was also very loud due to not having the exhaust system on it but it runs... and I am happy
Finished off a few more jobs... fitted the serpentine belt which was fun (not)... then extended the PAS pump feed pipe so it will clear the rotating bits... the VR sits forward compared to the 1.8t which sits back...
Fitted the new fuel filter and plumbed in the parts for the fuel pressure sensor...
Finally the hoses arrived!!! (better late than never I guess)
Tidied up and put the covers on the engine bay for a little teaser of the finished product... I also changed the coil pack covers and fitted a coil pack wiring cable conduit from the later 3.2 VR's fitted to cars like the A3 8P
Happy days
I am still waiting on a slim line fan pack to arrive that works... the LCR one is being returned for a refund and I ordered one from a TT V6 this time... arrived today and found that both fans didn't work at all!!... tbh I am happy to buy new fans as I can get them for about 35 quid each but I am not paying 50 quid for a cowl...
The search goes on... I am in contact with this seller and it maybe that I just offer a small amount to cover the cost of postage and then buy new fans as the cowl will be of use...
Tomorrow I will wire in the fuel and oil pressure senders and tidy the ECU wiring up properly
<tuffty/>