MK1 2036cc 16v ITB's 200+ BHP Project 1994 to 2011

Thats very nice mate, always good when to see a car thats been owned and cherished for as long as yours. nice engine work too! should be a monster when its done!

Tom :wink:

holeinmk1 said

Thats very nice mate, always good when to see a car thats been owned and cherished for as long as yours. nice engine work too! should be a monster when its done!

Tom :wink:

cheers

hoping for 12sec 1/4's when complete , my mate has a rocco similar spec engine and he's in the low 12's.  :mrgreen:

Well time to get the bottom end complete and fitt the pistons.

JE Pistons come with very good instructions on the rings gap positions.





H-Beam rods fitted with ARP Studs 50lb/ft torque 3 times.

New Oil pump fitted.

Windage Tray fitted also.

Schrick Baffled sump fitted too.
Complete now all ready for the flywheel, clutch and Head.



Fit the 16v Head.

ARP Head Studs all fitted using ARP Thread Lube
 

1.9mm ABF Steel head gasket 83.5mm bore (1.5mm compressed)



Allstage Head Flowed and Ported



Cams lined TDC 11.2mm lift



Piper Cam Pulley will be set at 3Deg Retard.

New timing belt fitted

Sachs HD pressure plate, Helix 4 Puk ceramic paddle and lightened Hotgolf Flywheel.
 


Hopefully will be complete for June.

just an update on my project.

Exhaust heat wrapped




Moved the MK1 to get the engine is easier , and cleared the engine bay for the new engine and radiator. Alot of the existing wirng looms will disapear too.

 


020 Gearbox 3.94 final drive & Quaiffe LSD , TSR Linages, short shift & weighted shift ready to go in too.




Well had a busy night, got the Engine and Gearbox bolted in place.


Pulled the  old K-Jet Loom out first to make room, its amazing how much room you have under the bonnet when yo get rid of the K-Jet.

Only two wires i'm not sure what to do with apart from that it all comes out.

Two cables are the Oil pressure warning senors.    



What a struggle thou fitting it on your own !

Also got the Pace Radiator off Benny for the project, which is ideal for TB's


Radiator in position, Oil cooler will have to be moved to the N/S to clear the air flow to TB's


New water manifold fitted for new hose set up.

Also side hose flange fitted with Temp Stat Adaptor on it ready for water temp sonsor for the Microsquirt

Throttle cable fitted to check fitting and size.

TSR Gear Linkages put back on ready for action.


Started assembling the Throttle Bodies

First step is to drill and tap No4 for the vacum pipe for the Brake servo.  







Next step fit the Injectors and the Fuel rails & TPS Switch fitted too.

 



Then fit the Trumpets , which it looks like are got to be tight under the bonnet.


Trial fit on the spare Head in the Workshop

 




Still waiting for FSE fuel pressure regulator to arrive so i can complete the installation.

and then get on with the wiring and Microsquirt ECU Mapping

As you said jenvey dth t/b,s with 90mm ram pipes on an abf in a mk1 does indeed get very tight especially if trying to use an air filtration system.

This is looking awesome mate 8)

just stumbled across this, looking really good mate  :y: will keep my eye on here, really like what you've done so far

Update  

Just fitted the Jenvey 45mm DTH Throttle bodies to the Engine.

Looks like they will just clear the Bonnett, don't know about Air filters though.  





Then fuel lines connected, ready for filter and FPR fitting .



The throttle cable needs a spacer fitting to get a straight pull on the Throttle mechanism
 
The standard throttle cable fits fine

Keep it up, excited about almost getting it in?

Update

Started work sorting out the old 16v loom now, a few items that need to stay Oil Pressure warning signal, Rev Counter, Starter motor  etc.




Also got a couple of RamAir filters to fit, they needed a bit of attention from the Stanley knife to fit them with the nice big Trumpets []   



Think the bonnet really needs to Jigsaw attention.


One thing for sure it's starting to look like a complete engine now. [:y:]




Just waiting for new Oil cooler pipe to finish the plumbing, and then its all Electrical from then on.

Also  lowered the T4 today with 55mm Jamex Springs.

Barrowed the ramp at my local garage to make it easier, it only took 1 hour to do it all.








Update - Twin Oil Cooler set-up & Remote Oil Filter repostioned.

New Brackets Made and the Oil cooler has been moved to the N/S above the Pace Radiator.





Remote Oil Filter has been left at the O/S but moved 6" across to give a clear air way to the Throttle Bodies [:y:]







ECU to install tomorrow and wiring to sort tomorrow.

Nice, cant beat a bit of engine porn. Does that mean you're gonna have to stick a scooby bonnet scoop on the car to feed the twinnies?  

No it will have a Carbon fibre bonnet with removable panel for the 120mm Trumpets  for events.  

The Oil Filter has now been moved another 150mm to the O/S behind the Headlight.

Microsquirt ECU & Fuel pump Relay mounted in the Scuttle Tray.


Loom routed through the bulkhead, i will fit a blind grommet after its all complete, coil pack to be fitted to the bulkhead once a bracket has been made.


Injectors & Water temp sensor connected



The engine bay looks alot better now all the old loom has gone.


The Grill has be drilled for extra air flow to the Oil cooler the holes will disapear soon and the complete slot will be taken out.




Only item left are the crank position sensor to mount and the wiring final connections the throttle position tail is too short so that will need extending [:y:]

mk1. said

Brookster said

Just booked the MK1 in for mapping on the 19th June @ MtechAutomotive

looking good[] you could of tried Wayne at Chipwizards he`s only up the road  in Rochdale,he can map just about anything.

cheers [:y:]

wish i'd have knowm i've paid for it now already, i'll get him to re-map it when its run in then.  []

Crank sensor now mounted ready



made two types of spacer this one and one made from 10mm steel bar in 5 layers but it needed abit of filing to get it in so will stick with this for now.

Also found a PAS Bracket in the garage that Chris has shown above, but that would need 20mm of spacers fitting.  


Also fitted the coil in position.



and finally MK1 back on all 4 wheels after 3 months on the stands.

almost completed. [:y:]







Bonnet fitted and bonus !! it shuts without cutting it or removing the 120mm Trumpets []
 

Looks great bet it sounds and goes great aswell,Ive always liked the look of a 16valver in a mk1 it just belongs there

Just read the whole thing, massively envious but im hoping to be a step closer soon with a purchase of a 16vlump :mrgreen:

It goes for the Microsquirt set -up checking & Mapping on Friday @ Mtech Automotive  so will be interesting to see the set -up.  :mrgreen:

Then the running in period  which i always find hard work.   

Cracking set-up, well done. Would running smaller trumpets give better cooling air as you'd be in the direct grill airflow & does the bumper being fitted effect water cooling temp?

Cero said

Cracking set-up, well done. Would running smaller trumpets give better cooling air as you'd be in the direct grill airflow & does the bumper being fitted effect water cooling temp?

Longer trumpets gives higher torque due to higher air speed into the inlet.

The bumper is getting 6no x 50mm holes drilled in front of the radiator to assist cooling when i get chance.  

Reeves MK2 Style