I've chipped away at this, each night. Finally it runs (again).
Ordered some silicone hoses for the intercooler pipework. Surprisingly not many at all. The pipe run is very short, which is great.
I had enough coolant pipes to fashion what was needed for the radiators new position and header tank inclusion.
Fresh gear oil, cheapo running in oil and fresh coolant... and we were ready to go.
After faffing around trying to figure out why the starter motor wouldn't engage, it turns out the battery wasn't charged properly. Granted, it has been off the car for over 3 years.
Started on the button, idles sweet, no smoke
Also used the Snap-on red brick, to help verify everything was OK.
There are a few things I need to remedy this week:
- Power steering pump seems to be permanently on
- Boat load of codes to clear and/or investigate (most probably legacy)
- Idle AFR never got above 12..even when warm
- Water leak from one of my homemade joiners
- The fan didn't kick in
- Fit the turbo blanket properly
As well as re-assemble the front end.
It should then be ready for testing in the street, running up to temp, getting the brakes scrubbed in, going through the gears etc.
I've also not re-fitted the oil cooler. Mainly as I didn't know where to put it, but also was waiting on the thermostatic sandwich plate. Typically this turned up just a few moments after the car was running. Need to make some brackets anyway.
I need it MOT'able for a dry spell in Spring, so I can set about running the engine in (again). As it's not got a boost controller plumbed, it's just on the actuator of 8psi or so.
Long term is to install an EBC, which I already have, so I can get it back to up to a comfortable power level. No doubt this may require a trip back to Sir Chipwizards' as at peak boost (pre-rebuild) it seemed to hit boost cut above 20psi. Coupled with the 'major' changes of better compression, shorter pipe work, clutch etc.. it probably might need a tweak anyway.
Anyway, that's miles away. Plenty of things to remedy.
I've kept a list of what has 'changed' or been added/completed since the car last ran, in 2018. Quite nuts really, how much of a money pit it is.
New piston rings - higher compression
ACL main and big end bearings
ARP head studs
Head skim
Block skim
New WRC spec 5 layer Head Gasket
New stem seals
Saxo Diesel header tank conversion
GMC (Pace) Radiator and SPAL fan
MR2 Intercooler
Shorter Intercooler pipe run + more direct
New Intercooler Silicone pipes
Exhaust manifold wrapped
Alternator head shield
Re-positioned radiator and cooler with custom brackets
Arches sealed
Crinkle paint cam covers
Re-routed PCV system
Custom Turbo support bracket
Turbo blanket
Downpipe support bracket
Extra lambda port added (for ECU and wideband)
Fuel cut-off switch removed
Brake Discs skimmed
New Mintex road pads
Helix 6 paddle clutch
Helix race pressure plate
*Rear door cards
*EBC to fit
ECU relocation to inside the car
*Thermostatic oil sandwich plate/cooler
Re-connected oil pressure and temperature to ECU
Map sensor relocated to cabin
Block painted
*to fit