5 GT Turbo PH1 Pearl

[Turbell]

In the corner there looks to be a drain hole, I felt this hole from underneath when i was tracing the leak on Camprust ( it was dripping from that and 'wicking' down rear wash/wipe pipe into car ) I wonder if it's that hole that leads to so many 5's having rot in the window corners?
Good to see you've at least got good news in that area.

 

[MOS]

This could be an unwise decision...

 

[DaveL485]

Black...thats going to get HOT in the summer haha!

 

[MOS]

Black...thats going to get HOT in the summer haha!

Yearh! There's no sunroof, and the electric windows may not work But then again, what's the chance of for a proper summer?

 

[MOS]

The inside is painted black with this in a spray gun

It turned out quite well when dried up.

Then I decided to give the engine bay a go with some epoxy primer, after this I'm fairly optimistic!


I'm now confident I can spray paint also, så I bought some from a local body shop and tried it out.



It looks amazing! I almost want to lick it..

 

[DaveL485]

Looks great mate! Been considering doing my own engine bay too on the 21, I have all the kit - only thing I am short on is the patience to prep it haha

 

[MOS]

Thanks Dave!
You totally should do it I only prepped what's visible when the engine is in, everything else is not so important to me, but everything turned out surprisingly well. I'd prefer a more matte finish though..
My VIN number is totally covered in primer and paint, I have to figure out how to make it visible again

It's a great feeling the cover up all my work and different colors, and finally see some results.
Now I can start to prep the engine to go in, I will take it apart and see if anything needs replacing. Last time I heard it run it had a slight knock from the bottom end, and was pressurizing the expansion bottle. At the same time I will we prepping the body for paint..

 

[MOS]

Engine time! After the break.

 

[MOS]

So.. I took the best looking engine apart, I knew it had issues as knock sounds, blow by and exhaust gas in the water tank. To be honest I thought some new gaskets and bearings would fix this.

Clutch is brand new, turbo recently rebuild. Look at the production date of the clutch



Stripped down ready to disassemble. Nice to have an engine stand.




I guess this was the main reason for both the knock and blow by. 3 of the 4 liners looked like this.


The crank also don't look too pretty.. All journals and shells has large grooves, but otherwise looks brand new, i guess there must have been a lot impurities under the rebuild process.


This old spare angine look awfully tempting right now, I know it was a runner when i took it out, so it will just get a refresh, and keep the other one for spares. Or maybe, if something cheap comes up, I might consider B18FT..

 

[Big Steve - Raider]

I just can’t get excited about the b18... C1J, F4R(T?) or VAG 1.820v Turbo for me..

Keep up the good work sir!!

 

[Duncan Grier]

I just can’t get excited about the b18... C1J, F4R(T?) or VAG 1.820v Turbo for me..

Keep up the good work sir!!

2nd that or consider vag 2.0 tfsi

Must have a go in the F4R turbo option as no experiance

Great work, keep the updates coming

 

[DaveL485]

I just can’t get excited about the b18

Me either, it just doesn't have that pzazz does it?

 

[MOS]

I converted my old GTE to B18, it was rapid at high boost!! It's just an easy reliable upgrade that makes good power without any modifications, but there's not so many engines around anymore. So I stick with C1J for now.

 

[MOS]

The old engine is coming apart, I found rust an unexpected place WTF!!


What's the purpose of this system? Is it purely EGR?

 

[MOS]

This engine thing is taking longer than expected, and I'm not even taking it totally apart



Now to the cleaning and swapping parts.
Oh! and I found a crack in the exhaust manifold, so I tried to repair it..


Weld groove - Video
The crack is pretty long, so i made a groove to weld in. before welding I heated the metal with a gas burner.
After weld and flapdisc - Video

After degreasing the engine block, it's time to remove all the old white paint.


Nitro Mors does not work well with this paint, so all cleaning has been done with wirewheel..


Some 2K primer and 2K PUR paint gloss 10, which is the color and gloss I have chosen for all engine bay components - it's great stuff!



Minding this is not a complete restauration I'll leave some of the "nicer" bits as they are. Swapped the rocker cover and sump from the other engine. How many types of sump are there for a GT Turbo? mines are different from each other.


All brackets where covered in a thick layer of oil and rust, so they were also degreased and sandblasted, there are so many of them what the hell were they thinking?
Brackets - Video

And when you least expect it, there's a turkey on your car.

Looking much nicer..



Next up Carburettor, I wonder how that will clean up. It was running fine before I took the car apart..

 

[andybond]

Looks smashing that.
Have to ask why is there a turkey on your car?

 

[Big Steve - Raider]

How many types of sump are there for a GT Turbo? mines are different from each other.

There’s really only one type of sump for a C1J, the difference is the oil returns from the degassing pot (larger elbow) and turbo (different Pipe diameters)

great work on the rebuild by the way!!

 

[MOS]

@andybond Thanks! My neighbour has them in his backyard, they sometimes escape. Gotta be the ugliest most noisy and most stupid birds on earth.

@Big Steve - Raider Do you know which one is better? not that it matters, the one with the long tube inside is rusted through..

 

[Big Steve - Raider]

@Big Steve - Raider Do you know which one is better? not that it matters, the one with the long tube inside is rusted through..

You should see the main actual difference is on the outside of the sump?? The degassing pot return pipe could be longer on one. And the Turbo return pipe one one could be a different diameter on one..?

Use the best one out of the two, honestly makes no odds..

If you use the smaller turbo return pipe tho, make sure you use an old bit of pipe as a spacer go make up the gap for the existing (larger) hose on your car. The jubilee won’t work that well to squeeze the pipe down and not tear the pipe to

 

[MOS]

So, despite no updates lately, a lot has been going on. I try to simplify what I can as I go along, nothing is sacred, it may offend some OEM guys, but what the hell...

Here's a lot of pictures, they are not totally chronological, but i hope they make some sense somehow..

Fuel tank converted to "campus" style.
As a part of the simplifying route, and the fact I got a filler neck from a campus laying around it's a nobrainer to convert.
Converted from this type with a valve..

To this, don't know what the effect is, but I got rid of the extra valve..

Much better!



Fuel pump w. bracket modification.
I can't find the bracket for the pump itself, as I remember it was rustet to pieces, so I decided to try and make a new one, from what I have.
Found a exhaust clamp and modified it for the purpose.

Cut the clamp in two

Welded the clamp on a standoff, it look perfect to me I just need to find some soft lining for the inside. The clamp cannot totally fix it right now, but it should when the liner is in place.



Brake lines in engine bay.
As much I hate doing this, it's rather satisfying to look at when done..



Engine.
Now the brake lines are done, it's time for the engine to go in.



Scuttle painted
To finish off the wiring I have to paint the scuttle. I opted for my beloved PUR 2K paint on top of 2K primer.





Wiring harness's sorted
The engine loom was scrap, so a now one was ordered from Juracing - I recommend this guy, top quality!


While I had the both harness out of the chassis legs, I also changed them from the Campus, as they were in a lot better condition, some repairs had to be done though. Stupid as I am, I didn't take into consideration that the Campus has no fog lights, so neither does the turbo now..
The inside loom was also modified (the connector for thay aux tank was cut off) and freshened up.

Next week I should receive a carburettor in working condition, so when the rest of the wiring is done it should start right up

Can any one recommend some spark plugs and gear box oil? I consider ELF NFJ?