Obviously the timing was out by a couple of teeth and I never double checked it at any point between having the engine rebuild and putting it in and turning it over.

School boy error I know but I'll get it right this time.

looking good

the indicator light wont stop it starting my g40 has it on still need to get to the bottom of it

Headgasket set is sorted Steevo...you'll have it for Wednesday mate.

Well...?

Head is on with the new headgasket.

Timed up, spins over fine by hand and on the starter.

Just got to connect up the fuel and boost pipes and she should be purring away tonight.

Pictures to follow.

is it running yet? you've had 4 days

IT IS ALIVE!!!!!!!!!

winner mate! bet your stoked

It runs and it runs pretty well considering I haven't timed it up with a light yet, just done it by ear just now.

But still one problem.

The oil pressure warning buzzer keeps going off. I have oil pressure as oil is getting to the head, I'm pretty sure of this.

But the damn buzzer keeps going off.

I've tried having the two connectors swapped round and stuff but the buzzer still sounds...anyone got any suggestions?

Also the rev counter isn't working but the digital clock, fuel and temp gauge are...thinking it might be the fact I'm running a coil off a Mk3 Golf GTI just now but dunno if that would make a difference?

Suggestions please :)

I seem to remember reading somewhere about later L reg and on clocks causing problems with the oil pressure sensor on earlier cars or vice versa. Can't remember who it was that had posted about it. May be worth an ask on club G40.

Glad you got it running!

Edited 23 December, 201114 yr by randombadger69

Haven't updated this in a while but thought I would now as a major issue came up.

Been running ok up till now, not on the road yet but was driving fine but I noticed on startup it was really tappy but then calmed down.

Also sometimes has a little 'tappy' spell when its running so thought only thing it could be is the oil pump.

So today I've pulled everything off the engine ready to take it out and do the pump.

Going to tidy up a few other loose ends while the engine is out now I have a nice dry garage to work in.

Pictures to follow soon, but for now anyone have any experience changing the oil pump on these? Hints/tips?

Would this be the G you flew down to drive back? Sockmobile?

Looking good on the work front

Jon.

Well since I haven't touched this thread since June I might as well do a quick update.

I'll apologise in advance for the crap pictures but they were taken with an iPhone not my camera.

So in the last update I said I thought the oil pump was playing up. Well I decided since I couldn't make the show this year that I may as well try and do shit right. So I pulled the engine out again in preparation of swapping the pump.

There she is out the car ready to be stripped.

After a bit more work the pump was out and it seems it had a fair bit of movement on the sprocket end which I can only assume caused the drop in pressure I was noticing.

So here is the pump in bits

So thanks to Ross (13kpologt) on here I was equipped with a new oil pump.

No pictures of it being built up as I just fired on and got it done but here the engine is after being placed back in the bay (a clean bay as I thought I'd strip and clean everything while it was out).

Then not long after everything was built back up and it was ready to rock and roll again.

Still got a few niggly little things to complete on the car but I'm not rushing anything as I want to do things right first time.

More updates and better pictures to come soon.

Didn't realise I hadn't updated this since October last year.

Well due to lack of time, money, will and patience I basically haven't touched the G40 since then.

Had a few issues some major and some not so major but it has lead me to the conclusion I need to start again.

No idea how far back I'm going to go, a factor making the task a little harder are Volkswagen telling me a good number of the parts I may need to replace, rusty bolts, brackets etc were discontinued in 2009/10.

Anyway strip down so far has gone as so.

Had the lump in and out so may times now I'm thinking of attempting a record for an engine swap on a mk3 just for a laugh.

Anyway engine came out, stripped it down to just the head and block and turned it over by hand. It should be relatively easy to turn over, but I had to be quite forceful with it. Cam timing was perfect but I feared the worst (bendy valves) but once the head was off it turned out not to be the case.

The cause of all my issues then....the valves had almost welded themselves into the guides somehow. Which would explain why even the new starter struggled to turn the engine over more than once.

I've cleaned everything up and sent the head away to be skimmed, turned out it was warped as well so that wouldn't be helping matters.

Going to be replacing everything on the head bar the valves themselves as they cleaned up really nice in the end.

Sometime this week I'll get the nice freshly skimmed head put back together and clean up the block ready to put the head back on.

Won't be going back in the bay just yet though, thinking about repainting the bay as it's full of scratches from previous engine removals...and the battery try has started to go so I'll get that welded up and painted too.

Also on the look out for a mk3 donor car to steal random nuts and bolts from as I've managed to loose quite a few over the years.

Oh and for Jon (KO3) I haven't found any more socks proping anything else up in the car!

I have a car in my garage about to be scrapped, what do you need? I may have...

Little update.

Got the head skimmed and then had the annoying task of putting all the valves back in. No pictures as I was too busy trying not to loose the rag too much and end up chucking everything in the bin in a big fit of rage haha.

But once that big ordeal was over it was time for the good stuff.

New head gasket :)

Then nice clean freshly rebuilt head on :)

There was a bit of conflict between the head set's guide for the torque settings and the good old haynes manual. The haynes wanted it 1NM more on the first 2 stages before the 2 lots of 90degree turns. So I opted for that just to be safe.

Then came the best bit, getting everything else back on and getting it all timed up :)

Now I just need to find the time to get it back in the car. The engine turns over a lot smoother and easier now by hand so I hope my issue has been resolved. I just need to get it in and run and not let it sit for too long I think.

So here is the engine and the G40 ready to be re-united :)

Hopefully I get time to get it all back together in the next couple of weeks, updates to follow.

Finally getting time (and the motivation) to get this project back up and running.

Since the last update, anyone who has read my GT build thread will know, I put the G40 engine into the GT just to try it out on the road after its rebuild. It was a complete success, the charger is starting to sound like it needs attention but I was going to send it away to JabbaSport this year anyway.

So the next stage is to get the engine out of the GT and back into the G40 shell.

I looked at the engine bay of the G40 and thought I can't put the engine back in their as it is. The bay is covered in years of dirt and grime and the paint is all scratched, picks of rust and starting to show through and it just generally looks a mess.

So I did this.....

Everything out of the bay so I'm left with this...

And all the dirt that fell out along the way

Next I'm gong to strip the paint in the bay back, treat the rust and give it a fresh coat of paint.

More updates to follow soon.

Nice work! Good to see you hanging in there!

Well the bay is now sanded back.

Turns out 99% of the rust in the bay was just surface, all been sanded back now.

Masked off, just waiting for pay day so I can prime and paint.

Any recommendations for paint? Will I just use standard bodywork paint? Hope I can still buy a colour to match the original.

Finally I got off my arse and made some progress, Look!!

Even started putting bits back on the car, trying to clean everything before I put it back on.

How it looks just now.

More cleaning and painting of parts to do but I'm pretty much just at the stage where I just bolt everything back together.

Well well well, this old thing...

Sadly after 6 years of ownership, countless strips and rebuilds along with lots of time and money I've decided to go no further with this car.

It has been rather unlucky for me even when I had the best intentions to get it running. Despite this it is the car that got me hooked on G40s and gave me the G Smile bug.

But now most of the parts are on my GT which just now is the main focus of my time and money.

This car is a bare shell now and is currently sitting in my shed next to the GT, so today I decided to seal it's fate by allowing repair panels to be cut off it in order to fix the rusty patches on the GT. I couldn't bring myself to do it so my mate who is doing the welding on the GT went in for the kill.

So original G40 J839PDD will never see the road again. It will donate many more repair panels for the GT, the mk2 and also for spares for the future.

Another one bites the dust! I take it nobody wanted to take it off your hands then? Bummer :(

Nope no one wanted it, it is a shame as it is a genuine G40, but it has been in a smash and had a repair to the passenger side chassis leg. So it was never going to be perfect without work.

Well you have a spare axle, trims, bumpers etc. Does it have a sunroof?

Edited 19 April, 201511 yr by dougstar21