harvey
Club Member
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Dave b's VXR Powered Gsi Diary
- Thread starter DavebGsi
- Start date
Wow Dave it looks utterly stunning. Well done mate.
Sooo I went for my test drive, wound the idle screw up so the revs stay up above 2000rpm, this is to bed the cams in and must be done for the first 20 mins!
Got the 20mins done, did a 25mile drive, little bit of boost, overrun, crusing, all the types of driving.
Got home, had a quick look over things and the engine was pissing oil out the rear main
I wasn't too impressed, after all this is the same issue I had before i Built a brand new engine, it's even a different block! But i guess I just haven't got the skills to fit one without leaking! So I ripped the box out that night and that was on the 24th and june and that is where it has sat.
TBF I have been on holiday and racing, but I was just moody with it and needed to take time off so I havent touched it.
So i got over my mood and pulled the sump off, which isn't fun when you have no box in it either!
Looks like there is plenty of sealer down the sides of the cap, but I think I hadn't put enough in the corners where the cap means the block on the mating face... annoying but need to just crack on.
New rear main seal, not taking any risks, and more sealer used this time, I have everything crossed it will be ok this time.
Because of summer and racing and the fact that alot of the car still needs painting, I can't see this being on the road this year now. There is just too much to do without rushing and I'm not rushing so I think I may just plod along now. Luckily I have spent all the major money now, but money has become tight for the next few month so may have to do some overtime with my free time so I am gonna get this back together, take it for another drive to make sure it's ok, then start with all the other jobs that need doing!
Got the 20mins done, did a 25mile drive, little bit of boost, overrun, crusing, all the types of driving.
Got home, had a quick look over things and the engine was pissing oil out the rear main
I wasn't too impressed, after all this is the same issue I had before i Built a brand new engine, it's even a different block! But i guess I just haven't got the skills to fit one without leaking! So I ripped the box out that night and that was on the 24th and june and that is where it has sat.
TBF I have been on holiday and racing, but I was just moody with it and needed to take time off so I havent touched it.
So i got over my mood and pulled the sump off, which isn't fun when you have no box in it either!
Looks like there is plenty of sealer down the sides of the cap, but I think I hadn't put enough in the corners where the cap means the block on the mating face... annoying but need to just crack on.
New rear main seal, not taking any risks, and more sealer used this time, I have everything crossed it will be ok this time.
Because of summer and racing and the fact that alot of the car still needs painting, I can't see this being on the road this year now. There is just too much to do without rushing and I'm not rushing so I think I may just plod along now. Luckily I have spent all the major money now, but money has become tight for the next few month so may have to do some overtime with my free time so I am gonna get this back together, take it for another drive to make sure it's ok, then start with all the other jobs that need doing!
Todd100
Club Member
I feel your pain with rear main seals, I did mine twice before giving up and sending it to Courtney sport to do
Yea mate, I am in exactly the same boat. old engine always leaked out the rear main new engine leaks out the rear main. bloody emotional! Very easy to get disheartened when that sort of thing happens but i have no choice but to get on! It was pouring out aswell
The main problem is its such a massive job to do aswell!
Today i got the sumps on, flywheel on and clutch on so tomorrow the gearbox is ready to go back in! hopefully will have most of the car back together tomorrow evening ready for the moment of truth test drive.
if it leaks this time i ******* scrapping it!
Hopefully all goes good this time ..
cheeky dibs on parts though if your scrapping it
are you selling your spit by any chance ?
cheeky dibs on parts though if your scrapping it
are you selling your spit by any chance ?
I am selling the spit yea. I'm sure I had a conversation with someone about it and they were gonna collect it next time they were down this way, but I can't remember who it was and I can't find the conversation either haha.
harvey
Club Member
Bejesus what a complete pain, all those highs followed by a massive low. Don't let it beat you and keep on tinkering, you'll sort it for sure and become triumphant in the end. Chin up and go polish something to take you mind off it before coming back fully refreshed and focused 
It's all good news! THE REAR MAIN IS FIXED 
.
A quick run down the road, a quick check looked good.
checked over, Filled the tank and waited several days for some decent weather but finally... there was some. Roll on 150 miles of running in round essex...
Bradwell Power Station
Hanningfield drag strip... I mean reservoir lol
And done!
I managed 120 miles before heading home, also went out the next day for a quick blast so total miles ended up at 139! close enough lol.
139 miles is definitely enough to know if there is any i=issues with the car and it all seemed pretty sound. It needs a big spanner check now. But nothing major to report apart from tracking being off, a few rattles but pretty sure thats the tailgate i threw on, engine sounds strong and smooth, boosts up very quickly. Obviously I didn't smash it, but to bed an engine in the theory now days is just drive it. On off the throttle , load, bit of boost, plenty of overrun cause that cools the piston rings down as the rough finish of the bores makes the rings hotter than regualar.
But i did give it a bit and its very willing to come on boost!
The map needs some work for driveablity but I can sort that out at a later date.
But overall I'm truley buzzing. It all works and its given me the drive to crack on.
The list now includes....
spray the roof, rear bumper, side skirts, new tailgate
fit dash cam
sort out the fact the fuel pump keeps running on its own when the car is turned off ( weird hey )
offside rear caliper is still leaking dispite changing the seals once
refit the interior and get the headlining retrimmed.
No chance of it being done before the weather turns pants, So I will be making sure she is spot on for next year
.A quick run down the road, a quick check looked good.
checked over, Filled the tank and waited several days for some decent weather but finally... there was some. Roll on 150 miles of running in round essex...
Bradwell Power Station
Hanningfield drag strip... I mean reservoir lol
And done!
I managed 120 miles before heading home, also went out the next day for a quick blast so total miles ended up at 139! close enough lol.
139 miles is definitely enough to know if there is any i=issues with the car and it all seemed pretty sound. It needs a big spanner check now. But nothing major to report apart from tracking being off, a few rattles but pretty sure thats the tailgate i threw on, engine sounds strong and smooth, boosts up very quickly. Obviously I didn't smash it, but to bed an engine in the theory now days is just drive it. On off the throttle , load, bit of boost, plenty of overrun cause that cools the piston rings down as the rough finish of the bores makes the rings hotter than regualar.
But i did give it a bit and its very willing to come on boost!
The map needs some work for driveablity but I can sort that out at a later date.
But overall I'm truley buzzing. It all works and its given me the drive to crack on.
The list now includes....
spray the roof, rear bumper, side skirts, new tailgate
fit dash cam
sort out the fact the fuel pump keeps running on its own when the car is turned off ( weird hey )
offside rear caliper is still leaking dispite changing the seals once
refit the interior and get the headlining retrimmed.
No chance of it being done before the weather turns pants, So I will be making sure she is spot on for next year
TubaMagna8
Club Member
Can you let me know how and where you get the headlining re-trimmed please 
So pleased for you that its not leaking oil mate!
So pleased for you that its not leaking oil mate!
Can you let me know how and where you get the headlining re-trimmed please
So pleased for you that its not leaking oil mate!
Yea will do mate, I am actually trying to decide which colour to go, I don't want to go black cause I think it make the inside of the car to dark, but maybe like a gun metal grey colour.
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retrim the headlining yourself its really not hard. Actually compared the what you've done you can do it with your eyes closed
Yea I have thought about it, I tried re gluing the standard one back on a while back and made a right mess of it! The spray glue kinda soaked through the material in the end and it ended up looking like ****!
I'll await results of the headlining as mine is starting to peel, probably due to the sheer amount of damp that gets in there over winter lol.
Very good to see it's all running well now with no oil leaks
Very good to see it's all running well now with no oil leaks
Just a quick update, spent 2 full days on the wiring. Got alot done to be fair!
I spent the first part sorting out a few out standing issues I had.
The first one, the rear fuel pump would keep running after I had turned off the car! To be fair, the omex manual tells you to use an ignition live, but I tried to cheat and looped the perm live for the pump to the exciter side of the relay. This would be fine usually as the ECU earth the relay... However it turns out that when you turn the key off, there is still enough of an earth track through the ECU to leave the relay latched.... The only way to stop it was to turn the key back on and off again.
FAIL
Sorted that by nicking an igntion live from the traction control ECU which is no longer fitted, unwrapped the loom, ran a wire. Job done. pump now turns off.
Next the ABS light was on, I flashed the code using the paperclip method and found it was a fault for ' brake pedal reference'
Seemed strange this, the brake lights work....
So I got myself the wiring diagram, traced some wiring and found the issue. When I thinned down the rear wiring and end up with this...
Well the curl of wire is basically all Tow Bar wiring, but it turn out the wire from the brake pedal switch goes up here aswell, on its way to the brake light, another wire is spliced in and head back through the bulkhead and off to the ABS pump!
found the wire, rejoined, done!
Final issue, the central locking didn't work. I wired the alarm back in the other day a bit neater, but nothing..... Turned out the fuse had gone walkies! refitted, done... love it when its an easy fix!
Next, got myself a new dash cam, a Garmin one which is tiny, the size of a go pro. Now I could pretend that this is for secuirty and to cover my arse....
But really, its so I can watch back cool races I have The nice feature is it has WIFI so I can just download clips straight to my phone and show my mates I really did beat that car in a race haha
This is now in its own little fuse box behind the dash, the dash cam also has a parking mode module so the proxity radar records as soon as something is in front, then saves the video if an impact is felt.
This also includes the electric sunroof which used to always run off the glovebox wiring lol
Next up, wire in the subwoofer! I have also started fitted some sound proofing. I used to have flashing tape in here and it was an asshole to get off. But this car will never get sprayed again and is now mint. So when I did my running in miles, I decided the sound proof should go back in as it was very 'tinny'
Stereo in
Power cable and earth cable and main fuse fitted under the false floor
Love a sub woofer, this is still a road car so gotta have good tunes!
I spent the first part sorting out a few out standing issues I had.
The first one, the rear fuel pump would keep running after I had turned off the car! To be fair, the omex manual tells you to use an ignition live, but I tried to cheat and looped the perm live for the pump to the exciter side of the relay. This would be fine usually as the ECU earth the relay... However it turns out that when you turn the key off, there is still enough of an earth track through the ECU to leave the relay latched.... The only way to stop it was to turn the key back on and off again.
FAIL
Sorted that by nicking an igntion live from the traction control ECU which is no longer fitted, unwrapped the loom, ran a wire. Job done. pump now turns off.
Next the ABS light was on, I flashed the code using the paperclip method and found it was a fault for ' brake pedal reference'
Seemed strange this, the brake lights work....
So I got myself the wiring diagram, traced some wiring and found the issue. When I thinned down the rear wiring and end up with this...
Well the curl of wire is basically all Tow Bar wiring, but it turn out the wire from the brake pedal switch goes up here aswell, on its way to the brake light, another wire is spliced in and head back through the bulkhead and off to the ABS pump!
found the wire, rejoined, done!
Final issue, the central locking didn't work. I wired the alarm back in the other day a bit neater, but nothing..... Turned out the fuse had gone walkies! refitted, done... love it when its an easy fix!
Next, got myself a new dash cam, a Garmin one which is tiny, the size of a go pro. Now I could pretend that this is for secuirty and to cover my arse....
But really, its so I can watch back cool races I have
The nice feature is it has WIFI so I can just download clips straight to my phone and show my mates I really did beat that car in a race haha
This is now in its own little fuse box behind the dash, the dash cam also has a parking mode module so the proxity radar records as soon as something is in front, then saves the video if an impact is felt.
This also includes the electric sunroof which used to always run off the glovebox wiring lol
Next up, wire in the subwoofer! I have also started fitted some sound proofing. I used to have flashing tape in here and it was an asshole to get off. But this car will never get sprayed again and is now mint. So when I did my running in miles, I decided the sound proof should go back in as it was very 'tinny'
Stereo in
Power cable and earth cable and main fuse fitted under the false floor
Love a sub woofer, this is still a road car so gotta have good tunes!
So now all the wiring was sorted, I did a quick AMP draw check, I have messed around alot with the wiring and wanted to check nothing funny was going on.
Ignition on - 3.7amp
Ignition off - 0.12amp
Goes to sleep a few seconds later, doors locked - 0.09amp.
Perfect!
Today, I went shopping
Helper springs for the coilovers! Been meaning to buy these for years but they will help to stop the spring flopping around when the wheel is jacked up, not massive issue.... but it is technically an MOT failure!
I'll fit them, maybe sunday or monday.
Next up, I have some rear illuminated grad handles! I have probably owned these for about 5 years lol
So i branched off the OE interior lamp and ran the wiring to both sides
Then, I found an issue...
It turns out that maybe only the phase 2's had to holes in the roof structure for the light back to fit! There is no way I am going to cut the roof so I am going to look at maybe modifying the light to fit some LED's in it. I'll up date on that.
Ignition on - 3.7amp
Ignition off - 0.12amp
Goes to sleep a few seconds later, doors locked - 0.09amp.
Perfect!
Today, I went shopping
Helper springs for the coilovers! Been meaning to buy these for years but they will help to stop the spring flopping around when the wheel is jacked up, not massive issue.... but it is technically an MOT failure!
I'll fit them, maybe sunday or monday.
Next up, I have some rear illuminated grad handles! I have probably owned these for about 5 years lol
So i branched off the OE interior lamp and ran the wiring to both sides
Then, I found an issue...
It turns out that maybe only the phase 2's had to holes in the roof structure for the light back to fit! There is no way I am going to cut the roof so I am going to look at maybe modifying the light to fit some LED's in it. I'll up date on that.
Awesome Love the sub hahah, really miss mine!
Love the sub hahah, really miss mine!
Awesome
Sub is a must! The volvo has one in the dash and its pretty good for it's size, but I think when you are retro fitting, you will never get good bass without a sub
So today i decided to tackle a few more jobs.
First up, fit the helper springs, I have wanted these for years. Not only to keep the spring tight when the car is jacked up, but also allows more damper travel which is always a good thing. You can see what the spring does under full droop ( wheel jacked up )
Top nut undone, top cup off
I love this about coilover, spring change with the leg in situ
these are only 40lb springs, as apose to the main spring which is 450lb. So with the car on the floor they will be fully compressed. So I compressed the helper spring in a vice and measured it
and lowered the spring platform accordingly....
Jeez it doesn't leave me much for ride height adjustment Hopefully this shouldn't be an issue because I was happy with the ride height before,
so it should be spot on!.... eeekkk lol
It's ok as long as I don't want to go lower haha.
Did the same to the rear
Happy with that, i'll get the ride height dialled in when I get it on a flat floor and the car is all together
First up, fit the helper springs, I have wanted these for years. Not only to keep the spring tight when the car is jacked up, but also allows more damper travel which is always a good thing. You can see what the spring does under full droop ( wheel jacked up )
Top nut undone, top cup off
I love this about coilover, spring change with the leg in situ
these are only 40lb springs, as apose to the main spring which is 450lb. So with the car on the floor they will be fully compressed. So I compressed the helper spring in a vice and measured it
and lowered the spring platform accordingly....
Jeez it doesn't leave me much for ride height adjustment
Hopefully this shouldn't be an issue because I was happy with the ride height before,so it should be spot on!.... eeekkk lol
It's ok as long as I don't want to go lower haha.
Did the same to the rear
Happy with that, i'll get the ride height dialled in when I get it on a flat floor and the car is all together