AE92 GTi-16 Progress Thread

[KPARRIS-JONES]

Just did another coat of red paint on the new callipers today, looks way better but needs a couple more. If the weather is the same tomorrow they'll bake off really quickly again.

[KPARRIS-JONES]

No progress as such, but I have ordered in a sweet Billet Alloy Oil-Cap which cost £20 including shipping from the USA! It's way better than paying for a Brand name like Bl!tz (they want £83!)and it has the added touch of saying (Powered by 4A-GE on it. :D

I can't get the pics off eBay so I'll post them when it arrives.

Next week is half term and aside from simply revising I will have a day or two of working on the GTi at the garage.

My plans are to:

1. Drain Oil

2. Re-seal sump

3. Remove and Respray Cam Covers

4. Refit Cam Covers

5. Refill Oil

6. Adjust timing to get it running smoothly.

7. Try not to get white stains in my boxers after hearing the Ashley

8. Fit Drive Shafts

Obviously I will only get round to doing one of those things and it'll explode or something, but I'll try!

[dawesy]

lol. youll be fine, you built the engine and thats in one piece

[KPARRIS-JONES]

Cheers dude.

It's been a long day and I have achieved what I wanted to so that's o.k. I got the Cam Covers painted finally! I decided to do them in white, so I had to use paint stripper which is absolutely potent I have burns up my right arm... nasty. I got them downt to the bare metal and then my mate Adey primed them and painted them in 040-1 Lexus Super White and lacquered them heavily.

I also re-fitted the original Negative Earth-Terminal leads, shifted the speedo cable to remove kinks and cleaned a few things up in the bay.

Also managed to fit the plug cover which I think is amazing and really finished the engine bay! :D

Here are some pictures:

Cam Covers stripped of paint and prepped:

Painted:

Fitted:

Before;

After;

[Raistlin]

Nice job KP

[dawesy]

very nice.

are you going to pick out the lettering in another colour?

[KPARRIS-JONES]

Yeh I will be putting the lettering in red and black I think, or maybe silver. That is another decision I need to make later on lol.

I will be adjusting the distributor to get the timing right and also blocking the radiator leak if the engine sorts itself out soon enough. :D

What was the original colour scheme on the cam cover? What lettering was red and what was black?

And the oil cap has been delivered, I'll be fitting that too! May have my day taken away from me to help out with things around my Grans death though... :(

[Gordy75]

Looking really good kp, coming along nicely!

Ive done mine in red and it really makes a massive difference, im busy painting my lettering

white and silver and it is a very fiddly and time consuming job! (for me anyway! :ffs: )

The original lettering on mine was all black except the '16 valve' which was red!

will be good to hear how it all souds when you have it all running well!

Sorry to hear about youre gran!

[KPARRIS-JONES]

Hi cheers mate.

O.k. I'll probably stick to the standard lettering colour scheme then. Good luck with getting yours painted up!

I got it running slightly better but there is a problem that we cannot diagnose. The engine keeps hunting between 2 and 2.5k rpm and will not settle down even when choke comes off.

All of the vacuum hoses are hooked up and I know that I put everything like TVIS back in the right way. When the engine surges, there is a click from a little blue sensor thing and it goes down to 2k rpm and it then surges again. I cannot for the life of me figure out what to do to get the idling stable.

The blue thing that clicks:

In good news though, my engine oil cap has been delivered and it looks brilliant! I fitted it took a few pictures while it was in the sun to show how bright the covers are! :B More good news came in the form of my sunroof motor suddenly bursting into life and also I have discovered that all the electrics (that are still in work) including the heater and the tinted indicator strips aren't too dark for road use. Today was a bright day and they could be seen clearly.

Here are some pictures:

I love it!

And I revved her up a bit, the exhaust is bassy until 3k and then the filter takes over with an utterly pornographic whine/sucking noise and a sweeeeeet burble on overrun. I love the sound of this engine!!!

Any help with regards to the idling is much appreciated because I am now fresh out of ideas. I don't think that I have changed anything so I will most likely have to run off the fault diagnostics next time I get to her.

[dawesy]

oil cap looks sweet.

check the cooling system for air as that can affect the idle but im not sure thats your problem.

have you still got the stock airbox?

if you have try temp fitting that and see if the problem goes. seem to remember something similar when i had my 4A and it was something on the airbox lid

[KPARRIS-JONES]

Thanks I'll try fitting the standard box next weekend when exams are over. I need someone to identify that blue thing though!

[dawesy]

its a vsv of some sort. just comes up on the EPC as valve air control No1.

does the haynes book give any indication?

also check if the original airbox had a temp sensor in it, if it did it needs to go close to the new air filter.

[KPARRIS-JONES]

Yeh it had only one sensor in it and that was the temp sensor, I think that I do actually have the 127BHP MAP sensor engine. It is really quite close:

It sits right behind the cone.

Haynes doesn't say anything about it. What's an EPC btw? Sounds useful... :D

[dawesy]

electronic parts system. gives you all the part numbers for the bits on the car. ill do you a copy if you want. pm me your address and ill send one out at the weekend.

[KPARRIS-JONES]

PM sent, thanks.

Still can't think about what it could be making it surge so badly.... I'm going to take a much closer look at it weekend after next with my mate. Dunno if you'd be available Dawesy to lend a hand? It'd be good t have the hands of experience with me to help diagnose it.

[Gordy75]

With the custom induction im doing on mine ive had to drill a hole in the pipe for the

air temp sensor and then theres the tube going from on top of the throttle body to the

air-box which has a sensor meetingat the same area and a little hose going into the

filter housing after the air has been through the filter, on mine im cutting that section out

attaching a breather filter and tucking it away somewhere!not sure if this is ure problem

(or if my babbling made sense!) as you have said before that there is nothing on ure filter housing

like that but when I looked up 4age pics on google and looked at tvis versions the pipe goes down to

the gearbox area! ?

when I first got my gti it was idleing like ures, mine turned out to be the butterfly in my

throttle body wasnt sat right and had a constant gap! :ffs: The aux air inlet valve was also pretty

clogged up and worth sorting out as they cost £120 to replace!

Hope this of some use!

[KPARRIS-JONES]

That may just be it, one my TB there is one that's blocked off and the other is going free but I assume it was always like that! Please get some pictures of your standard setup so I can sort mine out! I think that you have the small port engine though which uses a MAF sensor while mine had a MAP...

[john905]

looking good bud, cam covers look nuts in white

[KPARRIS-JONES]

Thanks a lot mate. I haven't seen them in white before, I love it! Had some great comments on fb about them :D

Totally worth the effort!

[Dof]

lookd great mate!! wanna polish my spare ones...! does anyone know can i use bigport 4age HT leas on my smallport 4age.....i know d leads ave different connectors but if i change distrubutor cap and use a bigport spark plug cover....????!!!

[KPARRIS-JONES]

Hi mate, I don't know about that conversion, although I can tell you that it'll be hard to polish them seeing as they're Aluminium which tarnishes quickly. ;)

Please could someone get pictures of their intak setup!? Preferably on a Big Port TVIS motor so I can see where all my vacuum lines need to go to. :D

Thanks

[Dof]

yeah it'll take hours of sanding and polishing but it'll be worth it in d end!! very true but a few coats of heat clear coat will do the trick;)

[KPARRIS-JONES]

ok. That's good to know I thought they would just tarnish and that was that. Nice one. Get pictures up when you're done! :D

Would you mind taking pictures of where you're vacuum hoses go with the intake? Cheers.

[KPARRIS-JONES]

I think I have diagnosed what the VSV is for. It is my idle up Vacuum Switching Valve and it connects to the spare hose connector I have going. I'll have to find the hose but I think that's it. I'll report back next weekend. :D

[KPARRIS-JONES]

No luck at all with the GTi. It kept hunting when I tried various combinations with the VSV. It still makes me smile to hear it rev but I just can't get the idling to settle.

I really need someone to post pictures of their system now! Please, I can't think of anything else to do now... :censor:

Did however strip out the Honda Prelude leaving in only the dash and centre console. It looks mean and is my first step to helping my dad build it up as a track beast...