SRowells Black Rallye

[Eeyore]

So this was the last time the bay will look like this for some considerable time if not forever. Tom came over and it was time to get the bodies on...

First job was to unplug all the sensors, remove a few mounting plates, remove the manifold, remove the coil pack cover and coil packs, remove the loom and ecu. Also removed hte air box system which took at least several hours due to everything being made of rust and lack of bits for several tools. Ended up having to use a disc on the dremel to get all the nuts off.



gti6 runs 4 separate sparks where as the xsi and 1.8 run wasted spark. the 16v coil pack from lesser petrols will fit the mounting holes in the gti6 cam covers but fowls on the lugs in the cam carriers. Initially I tried grinding down the lugs so that i could always go back to having separate coil packs however this was still fowling and the metal parts of the pack were touching the metal parts of the carriers. Unfortunately I had to cut 5 of them off but ive got spare carriers so those can always be fitted in the future. The plastic cover also doesnt line up with the oil filler so that has to be cut around. So the answer is a lesser petrol coil pack does fit, can be used but does require cutting along with the carriers. A hack saw and a dremmel to clean up is the best way to do it. Not sure if im happy but if it works it works. Doubt ill be able to fit my carbon coil pack cover now




Next up PAS removed from the top bracket and my brand new rallye pulleys removed! theyre only 4 weeks old :/ Lugs are all good on the sump. Spacers fitted to the sump lugs, long bolts and PAS relocation kit fitted along with the PAS pump. Low pressure inlet for the pump is rotated 180 degrees to point up towards the reservoir. Autotensioner fitted to take up the slack in the aux belt. Bolt holes are there but not used on the rallye so required a bit of cleaning up so as to not shear the bolts.




Fans off. And the two rubber dampeners removed from the cowling and fitted under the nissens rad. Slimline fan fitted as the second one seems to be catching on the cowling.



Decided that whilst the front was off this would be a good time to fit the mocal 13 row cooler. Instructions say it can be mounted anyway but has to be up against the rad. Ive spoken to several people with track cars who have gaps between the two. Im looking to mount the cooler above the PAS pipes with about 2 inches between the cooler and rad. This is because I want to run two slim line fans and there simply isnt room. Tried a few ways of mounting as the pipes are pretty long and its difficult to get neat. Lots of room to play with with the stock fans removed.








and this is how things were left for the day. Cancelled a few things tomorrow so have another day at doing this.



I forgot to buy a whole load of things which I need however we seem to have found a new inlet manifold gasket and PAS relocation pipe along with the crush fittings. Just short of 8mm fuel line! Tomorrow i need to cut the PAS pipe before the pressure sensor and add the relocation pipe on both the low and high pressure sides. Also need to get the aux belt on and then PAS should be done. Mount the cooler and cable tie the pipes neatly. Then we are on to adding in the loom, bodies, wideband and gauges. Hoping to get it all done!

Working on the front theres a whole load of rust. Its very disheartening to see and the whole engine will have to come out at some point in order to treat it all and respray however nows not the time as I havent got the time or space to do it. I hope that itll last out for the rest of the year. If the engine blows or it needs to come out this will be when I get it all done. Ill make a start with arches and things in the mean time.

so yeh wish me and tom luck tomorrow!