Jonny's GT20s HDi Estate

[Dum-Dum]

Good work mate. Not sure I'm a fan of it without the grille.

[Jonny81191]

Turbo's already on Niall, I don't do things by halves

I'm thinking of painting the cooler black, gonna 'shop it first though. I might replace the grille yet, but I like the lairy look

Although I was gonna go for a drive this evening and despite the car being off the road for a couple of weeks, I'd forgotten to charge the battery. So I still haven't driven it yet

[Jonny81191]

Since the engine change, I've not done too much, just trying to save money at the moment!

I've sorted a few issues with the new engine, mostly sensors, and I've also cracked on with retrimming the interior. The whole of the rear bench is now complete, and I'n just tackling the door cards before I crack on and get the fronts done. Then hopefully get the headlining done before FCS

   

   

   

[Niall]

Jonny how much you going to charge me to retrim some gti door cards?

[Dum-Dum]

trimming looks good buddy

[Grant]

Love the trimming mate, looks well smart.

Guess you're gonna be doing Vaughan's next? lol

[Jonny81191]

Right, I'm gonna do a proper update, possibly repeating a couple of things but with some extra pictures and more detail.

Starting from my return trip from reading, when my aux belt decided to let go, and the AA had to come and rescue me!


20130203_202714 by 306racecar, on Flickr


20130203_221022 by 306racecar, on Flickr

Soon afterwards, I had all sorts of issues with valves sticking, an issue I still haven't got to the bottom of. End result, I fitted another head and she ran fine. Until this happened..


20130225_203909 by 306racecar, on Flickr

So a new cambelt was purchased and fitted, and off we went to germany.


IMG_3094 by 306racecar, on Flickr


IMG_3329 by 306racecar, on Flickr


IMG_3367 by 306racecar, on Flickr


IMG_3462 by 306racecar, on Flickr

On the return trip from Monaco, the aux belt let go again, this time going through the cambelt cover at 4500rpm and causing the belt to slip and the valves to have a slight disagreement with the pistons. Which meant that 2 of the 4 sets of rockers got smashed

So the epic attempt to get her running on 2 cylinders began.


602057_10151554040953570_1084291984_n by 306racecar, on Flickr


560198_10151554042783570_1565863667_n by 306racecar, on Flickr


488067_10151554042493570_587295239_n by 306racecar, on Flickr


558024_10151554042618570_293407373_n by 306racecar, on Flickr

The belt had gone round the bottom pulley. Good and proper.

[Grant]

Holy crap @ that belt! Thats a better effort than Matt!

[Jonny81191]

So we stripped out the cam to have a look.


552987_10151554043143570_1894580739_n by 306racecar, on Flickr


3597_10151554043358570_1402342928_n by 306racecar, on Flickr


532230_10151554043208570_407100612_n by 306racecar, on Flickr

All of what we fished out.


562379_10151554043413570_28808093_n by 306racecar, on Flickr

Needless to say, we failed to get her running, so decided to leave her in lyon, and return with 3 cars to England.

Then Vaughan and I went on an epic roadtrip to recover the beast, hired a van and made the whole round trip in just under 19 hours.


Untitled by 306ep, on Flickr


Untitled by 306ep, on Flickr

After getting the AA (under protest, they don't like you attempting to fix it) to bring me home, I sourced a replacement engine from the scrap yard.


20130427_144253 by 306racecar, on Flickr

That had a bit of coal around the injectors.


20130429_181742 by 306racecar, on Flickr

So Carl and I, along with Chris, Linzi and Phoenix, got the old lump out and the new one dropped in with my GT20, clutch, and FMIC all fitted as well.


20130427_163904 by 306racecar, on Flickr


20130504_130143 by 306racecar, on Flickr


20130506_194512 by 306racecar, on Flickr

I removed the PAS and Aircon while doing the swap, to reduce the aux belt length as much as possible I also relocated the battery to the boot to free up some engine bay space.

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I fitted a "Group M" bottom engine mount too


20130429_214513 by 306racecar, on Flickr


20130429_214439 by 306racecar, on Flickr


20130430_183803 by 306racecar, on Flickr

Being so skint, I had to collect all the left over oil to stick in..


20130430_211535 by 306racecar, on Flickr

So got her up and running, and apart from a few small issues such as the battery not charging and me having to put it back in the engine bay, and dumping all the coolant out (forgot the bloody hose clip didn't I. /facepalm) she runs sweet.


20130508_202020 by 306racecar, on Flickr

Changed the fuel filter, that was a *tiny* bit dirty don't think it had ever been changed!


20130514_173258 by 306racecar, on Flickr

Since then I've been on a money saving mission. Even so, I fitted a 3" exhaust and a new cone filter


20130710_172636 by 306racecar, on Flickr


20130710_173901 by 306racecar, on Flickr

And just this evening I decided the interior needed some slight adjustment


20130715_185526 by 306racecar, on Flickr

Which brings me roughly up to date!

I need to get a remap sorted now though, more fuel at the top!

[Poodle]

Just a thought, are you running a lynx bottom pulley?

[Jonny81191]

Yeah I am, how come?

[puglove]

fair play Jonny if this was mine id had a tantrum beat every panel in an left it on the side of the road for ever lol.


oh and sounded epic up the hill

[Piggy]

shame I didnt see this, was hoping to...but well done johnny for sticking at it.

hoes that s2000 filter holding up?

[Poodle]

Interesting. You know a few other people have had aux belt issues - tom1357, bryn and warlord off the top of my head - all had lynx bottom pullies i believe.

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And Sean..?

[Arron]

That mint.

Have you had this rr with the gt20.

[Piggy]

is this the only stripped out estate?!

[Jonny81191]

It's not stripped any more, tempted to do it again though.

[Dum-Dum]

Ian (PE02HKG) has his china estate on rotas stripped.

[puglove]

It's not stripped any more, tempted to do it again though.

Nooo dont do it, its a estate................. how are you going to get the family back and forth with no rear seats

[Dum-Dum]

It's not stripped any more, tempted to do it again though.

Nooo dont do it, its a estate................. how are you going to get the family back and forth with no rear seats

TBF of his family are all jonnys size he could install hand rails and they could stand.

[puglove]

It's not stripped any more, tempted to do it again though.

Nooo dont do it, its a estate................. how are you going to get the family back and forth with no rear seats

TBF of his family are all jonnys size he could install hand rails and they could stand.

............. and would prob still need booster seats to stand on

[kingy]

Nice job on the retrim. Did you have to take the old cloth off?

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The door cards im on about

[Just Sean]

Never had a problem with my bottom pully!

[Jonny81191]

[attachment=12361]

Shiny bits!

Hopefully soon there will be some more updates to this, I've got a lot planned for 2014

[mcglynn]

Only seeing this. Might torture you at some stage for fitting help on the gt20 as I plan o perhaps getting an engine and building it with turbo etc at the one time! Love the car btw looks epic!

[Piggy]

oooooo b4s/6s/8s??

[Eeyore]

what are those? theyre like coilovers but without the adjustability? Theyre so big. How do you decide how high they are?

[Jonny81191]

Lol the boxes are wrong tbh. It's a game of guess the coilovers

[Dum-Dum]

Easy game, they'll be Niall's coiovers cos he bought Bilstiens and that explains the box.

[Craigus]

Easy game, they'll be Niall's coiovers cos he bought Bilstiens and that explains the box.

Well that ruined the game!