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androo007 wrote:Hurry up
Just ordered the last gasket i need for the downpipe to flexi and i think i may have the last bits needed...(black with red stripe) and connected the main battery terminal in the fuse box to the relay through a fused connection (25amp). Wiring is rated to 30amp and the relay is 30amp too.
I used heat shrink,solder and isolation tape and also made a small hole where the lid sits to run the cables and keep the fuse box dry. I think with a bit of persuasion it will come. Ive got the throttle body sock stuffed into another boost hose and clamped together which i am not too happy about but will have to do for now until i come up with something else. It maybe worth keeping an eye out for a st185 core as these fit better...(for a bit) so pulled her out again and carried on...
Do they look ok?
- removed the fuse and that was ok then broke down the circuits checking what was happening. Checked the relay was clicking over on ignition which it was. Then checked the earths and all good. Then checked the power at the pump and there was none - doh! left the fuse out! So put the fuse back in and had 9v at the pump. Checked the battery and the voltage was dropping real quick...Damn...the battery is knackered. Ive stuck it on the charger but i may just get it exchanged if i can find the receipt as it is under 3 yr warranty and not long ago charged it up and never even used it after i did. Also trimmed some of the pipework for a better fit. I keep trimming the core hoses but its still about an inch out.Ive managed to get the throttle body lined up but then its out on the turbo.
(to the rescue!) coming round again at the weekend and hopefully between us we can get it all lined up with the bits of boost hoses we have left...
(and a nice discount for cash) i bought a nice shiny twin piston bov for my car....ok its a rev 2 so i may suffer a bit with the afm but i am planning on going rev 3 conversion at some point so will keep it if it affects it too much.
It didnt look like any other pic i found of a st205 core on to a rev 2. I believe it may actually be a st205 bracket ive been sent. So we got inventive and made our own bracket for the throttle cable which works well.
(grrrrrrrrr). Just need to find or make another and then connect the decat to the exhaust backbox as soon as my gasket arrives for this.(on private road obviously) and then put the under trays back on and mot.(when money allows) a afr gauge and need to put a bolt to block the sensor place in the decat.
... i ripped the garage apart to find the decat bracket i purchased from a member about a year ago but did find it
The bracket to the block just didnt want to sit where i wanted it but managed to bolt it to another bracket down there which is nice and solid.
(magnetic sump plug showed no metal fillings and new sump washer fitted) i decided to give it a go starting. I have a nice hole in the decat where a afr sensor should fit which i havent got but thought it shouldnt make much difference. So i pulled the efi fuse and the king lead and with a fully charged battery i cranked it over a few times. It felt like bliss!!! Excuse the shiny bald head,baggy pants and moobs....my car clothes..... I kept checking the coolant in both engine and chargecooler and there was no leaks so all good so far.....
This is unplugged so im hoping plugging that back in when i install the fan in either the lid or the original position for a bit of extra cooling will clear this. If i dont do that then i read if i get rid of the fan ecu and relay the light will go out anyway so not a biggy. Now, i had the occassional problem with this previously but ignition on and off cleared it. However doing this a good 30 times and its still there. It clears first of all when starting but after a few seconds it comes back. Im gonna give the relay a whack with a spanner for now and check the fluid later but if not then i do have a manual rack and steering column to fit but that means more work and will need a good alignment afterwards....need to get this sorted either way before mot. I knew about this. When i removed the interior trim for something the wires came out the back of the aftermarket switch. They were fitted to part of the original loom with male spade connectors and i plugged them back in but obviously not in the right place as the fog tell tale light just stayed on and the rear fog lights didnt work. I just disconnected it for now so that needs sorting for mot.... I know there would be a blow from the lambda sensor hole and i have a bung ordered for this as couldnt find anything local to fit it for now so that should be here tuesday. All new gaskets was used so the only thing i can think is its blowing from the exhaust manifold area. I tried putting my fat fingers around various places but obviously it was getting hot plus the core,heat shields etc was in the way. It looks like the core and heat shields will need to all come out again which means all the fluid from the chargecooler core and pipes will need to be drained again and trying to get them all aligned again is a major task. I then have to try and find this blow which im guessing is the exhaust manifold so again and possibly more things need to be removed. Not sure how i am going to chase this blow without the core on it as it wont idle with the pipework off. I had hopes of getting to Japfest (tickets need to be ordered today) but i wont want to go without my car. I also need to get the mot done which isnt going to happen with the above problems....(PS and fog light and get rid of the fan light) but have been getting a real ear bashing lately because of the amount of time spent on the car. Now the engine was cold id thought i try and feel any blows and straight away i had a major blow by the top lambda sensor. I took off the sensor and found i had left some gaskets on the old cat so swapped these on to the new and used the proper nuts and that has stopped blowing. It does still sound like there is a blow somewhere but i am not going to look for this until the threaded bung arrives on tuesday for the decat. Plugged the old intercooler back in and the light went. The original idea was to fit the fan to the engine lid but the fan i have cant be reversed and wouldnt fit the way i wanted so I have just temporarily installed it in its previous position for now....so thats that problem sorted. I removed my bluetooth adapter from the diag port and linked out the relevant terminals to read the codes for the power steering (I cant remember what terminals now but shinny had a download of the relevant bgb section on his site). It said no power to the rack (flashed once then once). Checked the 80a fuse and that was ok so next on the circuit was the relay. I couldnt hear this clicking over so joined the two giant cables into one and the power steering now works and the light is not on. Problem not completely solved but ok for mot for now....will buy a new/secondhand relay when i can. Not sure what this relay is needed for actually? I checked the loom that it was originally plugged into for earth and live and then connected the aftermarket switch to these and afterwards all is working fine so nice easy fix there.(via a private local road obviously). The car was loud but boosting well to 0.8bar (will adjust the mbc after mot) and all was ok with the test drive apart from the indicators was flashing very fast indicating (see what i did there) a problem. I checked the connections and cleaned them and readjusted the bulbs and they are now both working.(like a very low tone honk truck stylee) but works so hopefully that is satisfactory. I am still not sure where to mount this so currently this just shows -160c lol. I realise now that installing a charge cooler means there is a lot more things that can go wrong now. A part of me wishes i kept with an intercooler but we will see how it goes. I just want a car that i can drive now! lol Not too worried bout club stand etc. I managed to gain access to the heat shield and exhaust manifold bolts by just removing the turbo hose and removing the 4 bolts holding on the throttle sock (not wanting to go through the hassle of fitting it back on the core so left the sock on the core) and removing the diy bracket for the throttle cable. I did notice I had a small leak on one and found that most of these water hosing wasnt tight so really tightened them up using a socket and rachet instead of a screwdriver. In fact 6 of the 9 nuts was finger tight! Maybe i forgot to tighten these? So using my torque wrench i managed to torque them all up to factory specs including the helicoiled stud. and i have no leaks!!"private" road just to check all was ok and everything is fine.(or maybe wed am i cant remember!) . Ive bought some new connectors as i wasnt trusting that the corroded connectors on the indicators was going to stay ok so will get these done tommorow. Even though it does work, it makes an awful swan type honk noise so should be able to access this now quite easily as i moved the horn to under the headlight when i fitted the bumper and gt4 chargecooler rad. Im hoping the emmisions are going to be ok now its got the decat on. I have a very slow puncture on the drivers front so will need to sort this to get the tyre sorted. Its been like this for over a year so will be ok till after the mot (if it passes). Im not too sure if its ok as it seems to go flat quite quick even when its not connected. I will just have to keep this charged until i can find the receipt. Maybe the car just needs a good run to recharge it. Its slightly different to the old one as had to run an earth from the terminal on the horn to the bracket it mounts on but all good now and sounds a lot better. When the car is running and road worthy i will try and borrow and ramp and get the trays on properly but they are secure for now............
Temp gauge stayed half way and no smoke like there was before the turbo swap..... and will update around lunchtime...................! Now enjoy her for the summer! 
The car is rarely driven in bad weather so may just remove them and wait for a group buy for a stainless set or something. Turns out i had the mbc on the wrong way round! Car is very quick and the chargecooler is all working fine and nice and cool to the touch unlike using the intercooler which just seemed to be hot all the time. Luckily, i managed to get a cancelled club stand ticket and passes for half the price. Also got some touchup paint to do the little bits of paintwork i damaged while working on it. Im not too bothered at the moment as i want to just use it. I may even hire a booth and try and do it myself....at the moment im thinking a candy green but may just go for a frozen white or something along those lines........