Helios Blue Campaign

jezzer said

Could it be a vacuum leak?
Where did you buy the exhaust system from?

Cant hear any leaks from the vacuum system, but is there another way to properly check the vacuum system?

The exhaust system is a budget one from ebay, think it was about £30 for the lot!   From the manifold back anyway, the manifold is an ashley 4 branch. The cheapo centre section and back boxes are just a stop gap until I can afford a custom system!

pet73r said

jezzer said

Could it be a vacuum leak?
Where did you buy the exhaust system from?

Cant hear any leaks from the vacuum system, but is there another way to properly check the vacuum system?

The exhaust system is a budget one from ebay, think it was about £30 for the lot!   From the manifold back anyway, the manifold is an ashley 4 branch. The cheapo centre section and back boxes are just a stop gap until I can afford a custom system!

Alright Pete , 
Give Lennox a ring mate , he will prob tell you over the phone what to try or worst case you will have to take it up to him but I'm 100% he will get it running 

albie said

pet73r said

jezzer said

Could it be a vacuum leak?
Where did you buy the exhaust system from?

Cant hear any leaks from the vacuum system, but is there another way to properly check the vacuum system?

The exhaust system is a budget one from ebay, think it was about £30 for the lot!   From the manifold back anyway, the manifold is an ashley 4 branch. The cheapo centre section and back boxes are just a stop gap until I can afford a custom system!

Alright Pete , 
Give Lennox a ring mate , he will prob tell you over the phone what to try or worst case you will have to take it up to him but I'm 100% he will get it running 

Alright Paul,

I think I may have sussed it… the Cam timing was out by about 8 degrees or something. I had lined it up with the top of the rocker cover and not the top edge of the cylinder head, so it was out a bit.

Well, I hope this will solve the problem anyway! Didnt get a chance to finish timing her up properly today so will hopefully get it all timed up properly tomorrow and go from there.

If that doesnt work I think I will have to call Andy, like you say, he will probably give me the answer over the phone! haha.

Got yours MOT'd yet?!

pet73r said

albie said

pet73r said

jezzer said

Could it be a vacuum leak?
Where did you buy the exhaust system from?

Cant hear any leaks from the vacuum system, but is there another way to properly check the vacuum system?

The exhaust system is a budget one from ebay, think it was about £30 for the lot!   From the manifold back anyway, the manifold is an ashley 4 branch. The cheapo centre section and back boxes are just a stop gap until I can afford a custom system!

Alright Pete , 
Give Lennox a ring mate , he will prob tell you over the phone what to try or worst case you will have to take it up to him but I'm 100% he will get it running 

Alright Paul,

I think I may have sussed it… the Cam timing was out by about 8 degrees or something. I had lined it up with the top of the rocker cover and not the top edge of the cylinder head, so it was out a bit.

Well, I hope this will solve the problem anyway! Didnt get a chance to finish timing her up properly today so will hopefully get it all timed up properly tomorrow and go from there.

If that doesnt work I think I will have to call Andy, like you say, he will probably give me the answer over the phone! haha.

Got yours MOT'd yet?!

Yeh that sounds like it could be a problem !
Got tyres on the p slots Monday and on the car now so might take it for mot Friday if this rain ever stops!! 

Excellent, inspiring thread

I was going to suggest some very good troubleshooting k-jet utube videos, but glad you got it running. Best of luck for your MOT.

Good news. Good luck with the MOT dude.  

Shughy said

I was going to suggest some very good troubleshooting k-jet utube videos, but glad you got it running. Best of luck for your MOT.

Its my mate Paul whose going for his MOT not me! Mines still in bits down my unit whilst I figure out whats wrong with it!  

Those videos would be greatly received! Thank you   

https://www.youtube.com/watch?v=a4fJAfXYxWk

Bosch K-Jetronic explained. Shows in good detail the basics and what to look out for. About 20 mins long but worth the watch I think.

- YouTube

Another on the warm up regulator. I guess if the timing is correct work back from the fuel metering unit testing all. I guess learning all the time…

Thanks Shughy, Will look at them now!  

Could you let me know where you bought your headlining from, do they supply the rear pillar pieces as well.

jezzer said

Could you let me know where you bought your headlining from, do they supply the rear pillar pieces as well.

My headliner is the original one! I very carefully removed it and then reused it as it was mint.

I think that Newton Commercials do the headliner kits, they are top quality, but they are not made of exactly the same material hense why I wanted to keep mine as I wanted the original stuff. Here is the link to their website
http://www.newtoncomm.co.uk/cars/vw-golf/model-134/roof-accessories/

My mate used one in his golf, check out his thread on here; abf golf 1.1c his username is purton

Hope this helps!  

Holy attention to detail!

Hi, have you checked the plunger in the metering head, this can seize\stick causing these kind of symptoms. Its easy enough to check, just unscrew the block with the injector lines and lift it off the flap housing. Mine was stuck after not being used for a long while.

Thanks everyone for all the help! And thanks to Shughy for showing me those k-jet videos. After I knew exactly how it worked everything became alot easier.

You all going to   when you know what was causing it to run rough, not idle, and soot up the plugs so bad!!

Turned out, I had a completely blocked air filter! I bought a NOS ramair filter from ebay. The thing was brand new, but must of been about 10 years old or something. I didn't make the connection until I took the metering head unit off to check the plunger. I found that the thing was so clogged up with oil that it was pouring all over the inside of the air box! The thing literally wouldnt let any air through. This was causing the mixture, which was already rich due to not being tuned yet, to be ridiculously rich! Causing the sooted plugs, trouble starting, misfiring etc etc.

That wasnt the only problem though I dont think. The flap that moves up and down has a little roller bearing at the end of it with pushes the plunger up and down. This bearing on mine had also completely seized making the movement of the flap very restricted.

So after all these little problems were fixed, she fired up first time and every time! Still wouldnt idle properly but she hadnt been tuned yet!

So, I continued with the build with an MOT booked. And a tune of course.

So, heres some pics for you!

Heres some after my first couple of spins up and down the estate…



ANd into my mates garage to get out of the wind so I could stick the stickers on!



And sticking the stickers on!



Lots of soapy water used, and a heat gun, making sure they are all straight.

Whilst I was in my mates garage I stick it up on the ramps so I could put the arch trims on, and splitter. Also put the black waitline trims on.

Here are a couple I took of the underside whilst she was on the ramps.











Wonder how long it will stay that clean?! 

Took her for her MOT, passed with flying colours  

Had her tuned up too, runs like a dream now. Still got a little lump in it now and again when cold but hopefully this will get better as it wears in, maybe  

She goes alright too   Can really notice the lightened flywheel.

As we all know with these projects, they are never really 'finished' are they?!?  

Still have a few problems to sort out…

- The tappets were ticking like mad at first, but I measured all the valve clearances and they were a mile out! So I adjusted these, but I messed up all my calculations   so could only adjust them to the tolerance levels. It sounds SO much better now, no half as tappity, but there is room for improvement. Will have to do this again soon.

- I also need to fit a stereo. The car never had one fitted, and I want to keep it that way, but I need some music to cruise to! Im going to get a small amp, and have 4 speakers in the original speaker holes and just run an ipod straight to the amp hidden somewhere.

- The exhaust rubbers are sh*t ones, so need to replace these with genuine ones as there is to much flex, the rear hanger of the exhaust it hitting the rear hanger of the car, which is annoying.

- There is also a slight blow from the exhaust manifold somewhere, which isnt helping the ticking noise at all!

- The new speedo cable is clicking like a bi*ch, which is very very annoying. Especially without any music to drown it out! Going to have to revert back to the old genuine one I think!

- Im waiting on my new discs to be machined down. I bought some rover 800 282mm discs, my mate is machining them down for me and drilling the 4x100 pcd. TSR wanted 165 + vat for a pair   . I bought two solid discs from GSF for £30 and he is turning them down for me.

- Need to have all the suspension aligned etc.

- Second gear is crunchy when changing down from a higher gear, anyone know what this is? Misaligned linkage?

- The heaters only blow hot air from the windscreen demister?! No hot air out of the front vents?!

Apart from those problems, shes finished!  

So here are some pictures of her 'finished'

Car looks great! The front vents are fresh air only. Did you have the gear box rebuilt?? as second gear crunch is a common problem.

chrissy said

Car looks great! The front vents are fresh air only. Did you have the gear box rebuilt?? as second gear crunch is a common problem.

Thanks Chrissy!

I didnt know that the fronts were fresh air only! You learn something new everyday…

I didnt have the gearbox rebuilt no, although I wish I had, after I fitted it everyone Ive seen as ask me the same question!! haha.

Its strange, sometimes it slips into second easy when changing down, but other times it a right bit*h. Its ok when changing from first to second.

Its not so much crunchy, perhaps that was the wrong word, more difficult to engage!