For the build, I'll let the pictures do the talking.
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All of this had to go into the engine:
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![Image](https://i.postimg.cc/jS6tFq3P/CIMG3615.jpg)
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The block bored and honed:
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![Image](https://i.postimg.cc/T2Zy8w04/CIMG3764.jpg)
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![Image](https://i.postimg.cc/ZY99D38N/CIMG3765.jpg)
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Crank, rods, pistons, water pump, oil pump and oil pan fitted:
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![Image](https://i.postimg.cc/VvbcBzbS/CIMG3772.jpg)
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Built head, had to be slightly modified for the high lift camshafts:
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![Image](https://i.postimg.cc/4nkRWjzW/CIMG3738.jpg)
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Turbokit:
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![Image](https://i.postimg.cc/gjK1Kr22/CIMG3734.jpg)
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Head, Turbokit, timing belt and cranktrigger fitted:
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![Image](https://i.postimg.cc/ydcMkLq9/CIMG3873.jpg)
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Robust and cheap VW parts
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![Image](https://i.postimg.cc/XvRMjTP4/CIMG3958.jpg)
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Cam trigger still missing the notch:
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![Image](https://i.postimg.cc/WzVQr0jy/CIMG3967.jpg)
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Fuel system stage1
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(SARD fuel rail, 850 Siemens injectors and Bosch 044 fuel Pump) this had to be changed later on in the build for the bigger injectors):
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![Image](https://i.postimg.cc/Wp6RVYwc/CIMG3970.jpg)
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![Image](https://i.postimg.cc/5yfRj1Sd/CIMG4684.jpg)
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I did a flowtest on the 850ccm injectors with the fuel prerssure at 3,6bar:
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![Image](https://i.postimg.cc/Y2xPZGtp/CIMG4744.jpg)
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The fuel rail is fed from both sides:
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![Image](https://i.postimg.cc/m22nsLr7/CIMG4720.jpg)
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As stage1 was deemed too small, fuel system stage2 went in:
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![Image](https://i.postimg.cc/L8J0JxLX/CIMG4767.jpg)
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![Image](https://i.postimg.cc/50VPk1GY/CIMG4813.jpg)
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I also flowtested the Bosch injectors, they flowed a bit more than the 850s
![Wink ;-)](./images/smilies/icon_wink.gif)
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Modified in tank pickup:
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![Image](https://i.postimg.cc/pL5qWpM5/CIMG4652.jpg)
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![Image](https://i.postimg.cc/9X1x16B0/CIMG4654.jpg)
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![Image](https://i.postimg.cc/bNBmf1Wj/CIMG4693.jpg)
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The old engine had to come out:
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![Image](https://i.postimg.cc/C1mwhwWX/CIMG4574.jpg)
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![Image](https://i.postimg.cc/HnL9fLtx/CIMG4572.jpg)
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I had a look at the cooling system and my raditor looked like this:
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![Image](https://i.postimg.cc/Y2X3Q1pm/CIMG4568.jpg)
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There might be a correlation with this damage:
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![Image](https://i.postimg.cc/W387WZgC/CIMG4570.jpg)
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So I fitted a new radiator support:
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![Image](https://i.postimg.cc/HnP9HCSt/CIMG4593.jpg)
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I moved my GREX oil cooler from it's standard location in front of the gearbox to the location of the standard intercooler:
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![Image](https://i.postimg.cc/8Pjb4j5X/CIMG4592.jpg)
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Radtech chargecooler core fitted in a place it was never intended for:
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![Image](https://i.postimg.cc/Y9M3zRGQ/CIMG4589.jpg)
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Gearbox ready for action:
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![Image](https://i.postimg.cc/VLxXFg25/CIMG4473.jpg)
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Wait, still missing the correct oil:
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![Image](https://i.postimg.cc/qMh8nSb9/CIMG3977.jpg)
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The engine ready to go in
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(at least that was what I thought at the time, I had to remove the intake manifold several times while the engine was in the car to change the fuel system, so much fun.
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).
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Yes, I did all the wiring myself.
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![Image](https://i.postimg.cc/44F6Ys56/CIMG4483.jpg)
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Hose and pump for the charge cooler:
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![Image](https://i.postimg.cc/nzhmLP9S/CIMG4634.jpg)
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![Image](https://i.postimg.cc/R0Rf4Bhn/CIMG4633.jpg)
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![Image](https://i.postimg.cc/sxtGwf6b/CIMG4595.jpg)
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![Image](https://i.postimg.cc/ydpZ3yF1/CIMG4659.jpg)
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I had to do some wiring in the trunk:
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![Image](https://i.postimg.cc/yxJSm3PF/CIMG4710.jpg)
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This is what I wired all those wires to.
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Very cool ECU with wideband control, boost control, knock control, launch control, map switching, engine safety diagnostic and so much more.
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![Image](https://i.postimg.cc/T1mn8WDT/2011-09-01-21-38-07.jpg)
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The engine finally in the car:
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![Image](https://i.postimg.cc/6qrbMC7s/CIMG4822.jpg)
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After all that I got a base map to run in the engine, as it clearly wouldn't run with a standard ECU
![Wink ;-)](./images/smilies/icon_wink.gif)
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The first mapping session revealed a few shortcomings of the build at that time:
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- above 1,4bar of boost it was leaning out as for fuel delivery not beeing up to the task, hence fuel system stage2.
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- my crank trigger didn't work properly as the ECU lost synch at 6900RPM, the gap between the sensor and trigger wheel was too big and the sensor was slightly misaligned.
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On my way home that day one of the COPs died, can you tell which one?
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![Image](https://i.postimg.cc/7LWzfN1x/CIMG4802.jpg)
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Since then I changed some stuff, like the hose connections for the idle valve, BOV recirc, cam timing, heat shields, etc.
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I also broke some stuff, like turbo inlet gasket:
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![Image](https://i.postimg.cc/xjR0517m/20130702_210848.jpg)
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and the turbo outlet hose:
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![Image](https://i.postimg.cc/j2zn30p5/CIMG4854.jpg)
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With that I went into the second mapping session which yielded the followig results:
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- the small air filter could not flow more than 1300kg/h of air
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(I have no idea what that is in cfm, sorry)
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- intake air temp at the end
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(7700RPM) of 3rd gear at 2bar boost is 55�C, 5-10�C less would be better
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(maybe a stronger pump would help).
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After that I changed the air filter location and the filter itself for a K&N Extreme which flows a whopping 1600kg/h at 2bar
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(the flow without a filter was only 1630kg/h, so it is a very good filter for it's small size)
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This is what the engine bay looks now:
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![Image](https://i.postimg.cc/MTY899sw/CIMG4866.jpg)
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As I drive the car every day I guess that more things will breake over time, but the engine has been strong for the 5000 miles it has been in there so far.
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I think I can get a dyno figure now and see what's what
![Wink ;-)](./images/smilies/icon_wink.gif)