Been a while since the last update and have had my fair share of issues to deal with, once all of the items I wanted to do over the holidays were completed the time came to actually drive it and considering its running a stock standard 1.8T ecu it actually runs and drives really well.
I was really surprised how well it drives and feels, not a lot of noise and seems pretty effortless. I don't think I'm making any boost for some reason but that's not a bad thing while the engine is bedding in.
A couple of trips down a very quiet road near work all seemed fine..................until the 3 mile mark..............a huge cloud of smoke coming back to work.
Cut a long story short it blew a hose clean off the oil cooler loosing around 5L of oil in an instant, oil over absolutely everything underneath. I've never had such an epic mess to clean up.
5 hours on the hoist degreasing and washing everything down, amazing where oil goes when sprayed under pressure!!
Fundamental mistake on my part, running an external filter and oil cooler both of these see unregulated oil pressure direct from the pump meaning it could be as high as 300psi pressure maybe more.
Normally you fit a pump cover with a relief valve but being a type 3 engine I don't have room, after looking at other options I settled on a Jaycee oil filter mount with a bypass valve built in which has a hose back to the sump.
Above 80psi it will send oil back to the sump doing the same job as the pump cover.
Very lucky that I'm running a deep sump as otherwise I think the engine would have been toast, with this deep sump I'm running more than double the original oil capacity.
Few weeks of waiting for parts to arrive yesterday I pulled the sump to drill and tap for the return line, changed the rubber hoses to the cooler for ss braided ones (probably not necessary but I'm not taking any more chances)
Ran the new hoses and buttoned everything up, primed oil pressure and all seems fine so far.
Hopefully this is it for a while and can now just concentrate on tuning the thing, this has by far been the most stubborn car ever as it seems it just doesn't want to be finished.