OEM+ Coupe 16v

Posted: Fri Dec 12, 2008 11:25 pm

Hi everyone

As some of you may or may not know i have been gathering parts to have a go at getting a little more from my little four pot.

I have finally managed to get a bit of time to use a corner in my dads garage, so i started on it this eve.

It all started last febuary when i bought the car. The guy i bought it off suspected it had a headgasket problems so i got it at a bargain price, as it turned out it didnt have headgasket problems afterall Very Happy

Alhought it did require quite a bit of TLC to get it right.

Anyway i have been using the car for the last few months and love driving it, it handles great and goes pretty well. However it has been using alot of oil Evil or Very Mad

I have come to the conclusion that it is very likely to be the valve stem oil seals.

So i thought wilst i had it in bits i might as well have a play and see if i can get a little more out of her.

Parts i have collected:

5 branch tubular manifold
Heat shield
VW Golf KR inlet and exhaust cams
Full headgasket kit
New genuine audi cam chain

And a few other bits and pieces

Soo...

Tonights efforts consisted of running the car with the oil and coolant flush, draining the fluids and starting the dissasembly.

Tomorrow i hope to get a full day at it and get to the point where i have the old manifold off so i can have a good look at what needs doing to mod the tubular one to fit (if it will fit) Confused

This is all fairly new to me although my dad is a self employed mechanic of the last 40 (ish) Laughing

years so i have grown up around engines, cars, motorbikes and a little engineering so i am quietly confident in my abilities and know when its going over my head Embarassed

Feel free to comment, offer critisism, help or advice.

P.s. i'll try keep the pics coming Very Happy

Posted: Fri Dec 12, 2008 11:47 pm

Here are a couple of pics of the car a few weeks ago after a good wash. (Also my bike which i completely rebuilt after having the frame powder coated)

Posted: Sat Dec 13, 2008 1:24 am

It'll fit, but you'll need to do some welding after removing a flange or two, not just as easy as cutting one runner and flange off.

User on here "Aspro" did this to his megasquirted, throttle bodied 16v.
Pics are dead in his thread, but I have some somewhere saved. Buried on some discs somewhere. I'll dig them out.
In the words of Scott, "I may be sometime"

Jase..
Wink

Posted: Sat Dec 13, 2008 1:32 am

That was easier than I thought.

Hope these help.

Posted: Sat Dec 13, 2008 7:45 am

Looks like a nice project and the car cleans up nicely, looks like a good starting base.

@jas that manifold looks nice, what happened to the car in the end?

Posted: Sat Dec 13, 2008 7:55 am

Hmm.... thats interesing, thanks for digging those out jase, massive help. I knew there would be welding involved but i wasnt sure if or what would need doing with the flanges.

The main aim is to get the car up and running agian by xmas with the cams in place and a bit of home brew porting on the head and with a good idea what needs doing to get the manifold in place. This is a buget(ish) project so this may have to wait as i will need to get the welding done, not confident enough to do that Embarassed

Cheers guys, keep em coming Very Happy

UltraUser Joined: Jan 30, 2003 Posts: 1743

cracking base for a project. Fitting the kr cams will make a massive difference. you should see in the region of about 170-175bhp when ure done.

@acidburn- it was for sale for a while but i think e might have ended up breaking it sadly

Posted: Sat Dec 13, 2008 10:48 am

Yep, it was broken up in the end at Eric's place. Almost all of the engine parts and the engine itself went to the VW Golf crowd IIRC.

Posted: Sat Dec 13, 2008 11:00 am

nice project indeed, should make for a fun car Very Happy

@ bike - CB One? or is it the 400? Very tidy nonetheless, I'm loving the retro Hondas Cool

Posted: Sat Dec 13, 2008 12:54 pm

nice clean coupe you have there matey.. Cool

Posted: Sat Dec 13, 2008 7:36 pm

Agreed

Don't see many in silver do you ...?

Interesting to see someone working on something reasonably standard.

Posted: Sat Dec 13, 2008 9:48 pm

Hi everyone, thanks for the comments Very Happy

The bike is cb400 Superfour, got it when i was 19 owned it four years now, i love it, could do with something with a little more grunt tho Laughing

Anyway back to the project.......

Balls balls balls Mad

..... Major disapointment today, got it all stripped down to the point i could try the manifold in place. Slotted in lovely..

Origional

Tubular

Started loosely fitting bits back in to see how things fitted

Seemed tight but feesable, then, notice the throttle body in the above pic, its probably hard to see but with the heatshield in place it sits about half an inch above the inlet manifold balls!

So i took the heatshield off and was left with it fitting but looked like this...

The throttle body is microns from sitting on the tubes of the exhaust manifold, as you are probably aware these run extremely hot and would almost certianly bugger it!

As this is a budget project i cant go any further with the tubular as it will require lots of expensive mods to make it fit. Either that or i do what aspro did and put it on a stand alone management system with throttle bodys but that will be expesive, take time and will make the car less street friendly.

Anyway, hay ho, the cams will still be going in and i will still be doing some home brew porting/polishing. Gona have a go at the throttle body too.

I'll keep you posted, head comes off on monday Twisted Evil

Posted: Sun Dec 14, 2008 10:35 am

Can anyone recomend a good long lasting hi temp spray for painting my inlet manifold and rocker cover?

Cheers

Jim

Posted: Sun Dec 14, 2008 10:55 am

My throttle body

20v throttle body

Golf throttle body

Why is mine so so restrictive on the smaller inlet?

Any help on this would be much apreciated, can i remove most of the bulk around the small inlet?

Jim

Posted: Sun Dec 14, 2008 2:57 pm

if you strip the throttle body down so it had no throttles in it you could just port it with die grinder you would be able to get it to that one pictured. will a golf one fit? if so i might have one you can have cheap if you want it? Smile

Posted: Sun Dec 14, 2008 3:46 pm

Not sure if it will fit actually, what about the position sensor? If anyone els knows i would be greatfull Very Happy

I was gona do a bit of porting on it anyway but i find it strange how it is so small.

Am i right in saying that the flaps open allowing more air to be sucked and therefore lifting the plate in the metering head letting more fuel through?

If that is correct then by opening up the whole more air will flow more eficiently lifting the plate more? Confused

Posted: Sun Dec 21, 2008 9:42 pm

Ok latest developments......

Not been able to get o with this as fast as i would of liked. Our family dog of 12 years had to be put down on monday, was a pretty shitty day. He was a really great loving friendly dog, rest in peace Roly Crying or Very sad

Ok so i managed to get the head off on wed evening after work and also managed to get all the valves etc out, i was left with this...

It is a damn good job i decided to take the head off because one of the water ways in the gasket had started to leak towards the sealing ring around the back cylinder, dad recons it wouldnt of been long before it went.

Once the head was off i started work macthing the ports up on the inlet manifold and the head, i found there was a fair amount of material to remove. Spent most of this weekend finishing off taking all the casting marks out of the ports (there was some quite heavy lines rinning right through). The head is now ready to be skimmed.

I also spent an evening last week messing with my throttle body and this is the result, not sure if im satisfied with it yet, i could go bigger but i dont want to mess with it too much, as it started off quite small, and dont want to end up with something undriveable at slow speeds.

before..

After...

Bits and pieces ready to go bak on the car, head is getting skimmed 2mora....

Posted: Sun Dec 21, 2008 10:11 pm

some nice work there jim Cool

you can take loads of material out of the 16v heads really makes em breathe better i took loads out of mine when i ported it Very Happy

Posted: Sun Dec 21, 2008 10:19 pm

Thanks Gompa Very Happy

Posted: Mon Dec 22, 2008 8:41 am

It would never of happened without all the help and info from this forum, thank you everybody Very Happy

Posted: Sat Jan 10, 2009 9:22 pm

Ok, she is up and running again Cool

wahoo, finally!

After much deliberation about cams (see my other thread in the series 3 section) i ended up putting my origional cams back in. I have not had chance to drive the car yet to see if the home brew porting polishing job on the head and throttle body has made any difference.

Finally got her fired up tonight about 6:30. Took ages for the Tappets to pump up, bet eventually they did and she ran sweetly Very Happy

Here are a few pics, i did a little tarting up in the engine bay while i was at it, also modifyed the cool air intake too, it still draws warm initially but it went through a very small hole in the plastic headlight shroud so i cut the hole out a bit bigger and put in a slightly larger diameter pipe, what effect this will have (if any) i dont know but i wanted to avoid drilling the airbox.

Painted Rocker Cover

All back together

So the engine is now back togeter but as with any project it will never be finished. After i get it back home and give it a wash i will take some pics of the other bits i been messing with Laughing

Posted: Sat Jan 10, 2009 10:05 pm

well done some nice work there jim you should have a better pull from lower down the rev range Very Happy

Posted: Sat Jan 10, 2009 10:35 pm

Thanks mate, thats what im hoping for Very Happy

Also got a remus back box to put on once they stop putting stupid salt down on the roads Evil or Very Mad

By then the bosal thats on it now will be well and truly bug*erd!

Anyone any experiance with the remus boxes? Got it off ebay, its like new really. Are they noisy? Dont really want noisy.

Posted: Sun Jan 11, 2009 9:23 pm

remus sounds good mate - sounds like you had a bargain there Cool

Posted: Sun Jan 11, 2009 10:19 pm

liking the cam cover, looking forward to hearing how this performs now Very Happy

Posted: Sun Jan 11, 2009 11:48 pm

Thanks guys

@ yodaboy - yeah thats what i thought!

@acidburn - Yeah so am i, im not expecting huge results just a cleaner rev range i think

Twisted Evil

he he he - just scored some ABF cams off ebay (shhhh, dont tell my mum) Will run the car as is for a while then slip them in when my parents aint lookin Laughing

Posted: Sun Jan 11, 2009 11:57 pm

Looks nice now, makes me want to clean my engine bay up a bit,
good work fella.

Si. Wink

Posted: Mon Jan 12, 2009 12:01 am

you make it sound like ABF cams are some type of class A narcotic Laughing

Posted: Mon Jan 12, 2009 8:46 am

lol maybe im hoping they are gona force my eyeballs out the back of my skull due to the HUGE extra power lol Laughing

(read sarcasticly of course!)

Wish i had cheep use of a dyno then i would do a before and after comparison to see if its actually worth putting them in!?

Thanks agian everyone Very Happy

Posted: Mon Jan 12, 2009 11:13 pm

Wahoo, drove the car home tonight, its so nice to be back in somthing that goes around corners and stops. Thanks to mi dad for letting me use his courtesy car tho (s reg fiat punto 1.2 16v ELX model - 85hp Very Happy

)

As its been a while since i drove it its hard to feel any differences. Definately seems to rev a little more freely and pics up a little better from bottom end!

Was it worth it? - definatly yes as i love tinkering and as the head was off anyway it would of been rude not to have a play!

Next plan - Fitn my remus back box as the old one is blowing like mad, wont supprise me if it falls off in the near future Laughing