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Cully's Stage 1 HDI Estate ongoing Project
#1
Cully's Stage 1 HDI ongoing Project

Ok heres my car when i went to view it before i bought it back in april 2010
was looking for a car better on fuel and with more room than an astra

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two weeks later i was the proud owner of a 2002 hdi, full service history, 12months Mot and 12month

warentee for the cost of £2500

so after driving it for only 1 week i start spending money on the car which hasn't stopped since really.
my first purchase was a KWP2000+ from china so i could have a go at remaping the car

this came quite quickly so off to read the ECU
i copyed the map file
the info from the ECU reads

0281010592 < this number is the same as the ECU number on the TIN !
1037353483
B075WFS
S03C81A0001
81_14G8
31325544

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having a friend that owns a garage buisness with a rolling road sometimes has its advantages
at this point we decided to get some standared power runs done for a bench mark
also we decided to give the car a decat

1st today Ive had done a standard power run !

2nd spent time removing the cat by knocking out the matrix then unplugged the EGR valve and air doser
followed by another power run !

3rd spent time messing with maf/filters/intake positions while running power runs


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my findings !!

On my car the cat was recently replaced so it weren't blocked so putting up no restriction !
this may point to the standard 2 box system restricts the system more than the cat alone !

air intake
the standard panel filter is more than up to doing the job as no changes to output were noted with or

without or changing the pick up point

the biggest difference was seen after we did a "Dyno Decoke"
holding car on load and spraying water into the intake to clean the inlet tracts (not through the MAF)
this seemed to release a few more Hp over the standard run

i Believe my car is getting the max out of itself
so is in need of a Remap!!!

a big thank you goes out to Mr Whippy for coming through with the stage 1 map tonight,
have been out and flashed my car with the KWP2000+ took around 3 Min's

now just got to wait for the drive to work in the morning

time to drill and tap the inlet so i can fit a boost gauge

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got back on the rollers to check the new map

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painted the dash plastics to match the car

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other catchup items i have done

OEM boostgauge fitment
link here http://306oc.co.uk/forum/viewtopic.php?f=29&t=142

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Fog flash with main beam mod
link here http://306oc.co.uk/forum/viewtopic.php?f=29&t=156

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Alloy referb to Gold

just a short guide on removing paint from alloy wheels

ready for repair and priming



i started off trying to sand the wheels down but that was taking ages so tried a different approach


Things needed

Alloy wheel to be stripped

Nitromors paint stripper

Paint brush

Wire wool

Rubber gloves

suitable place of work NOT THE KITCHEN TABLE

water/hosepipe



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place wheel on a flat surface


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pour some Nitromors into the can lid and with a paintbrush dab onto the paint that is to be removed



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once you have coated the wheel once you should begin to see a reaction, and be able to see the areas you

have missed.
reapply a second coat then work paste in with the paint brush.



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leave for around 5 minutes,
grab a handful of wire wool and begin to work the paste with the wool you will

find the paint will come off easy



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work your way around the wheel until you have removed all or most of the paint and paste



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the 5 minutes is just a guide i found this long enough to strip it down to the original primer


now i took the wheel outside and washed the rim off with water from a hosepipe be careful where the water

is spraying as the last thing you want is paint removed from your car!



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the wheel is now ready for repair or priming

Primmed fronts and backs



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backs painted matt black



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fronts being painted under halogen lights on a turntable stand



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four wheels in the house hardening off



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wheels fitted

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flashed a new map from Pro-steve with rolling road graph

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ooooww new springs dampers and bush's for the front

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list of new parts fitted
SPAX SSX Springs S027016 -40 springs
Unipart for (2002 HDI 18mmball,power stearing,abs)
UGCGSJ3079 Plastic droplink
UGCGSJ3533 Suspension arm complete
UGCGSJ3534 Suspension arm complete
UGCGSA10118 Front strut
UGCGSA10117 Front strut


also had to have my tracking done as the car was toeing in 7 deg's as a result of the lowering


for my latest addition to the car is a splitter from a renult megane scenic
remember to run the car onto extended ramps or you won't get the car off without riping the splitter off
fit splitter with self tapping screws, drill, double sidded tap and a blowtorch!

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Cully's Stage 1 HDI Estate ongoing Project - by cully - 17-12-2011, 08:02 PM

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