Will post photo's tonight.
Rob Green Motorsport did the conversion while it was still new and I hope it is not their work that we uncovered but other clueless people thereafter.
1. The fuel filter had no water trap and a second fine filter was fitted. I removed the second filter, redid the plumbing, replaced the filter with the correct filter, fitted the water trap I got from Dawid and had to change the electrical plugs as they did not match. The electrics I did while Michael had the intercooler off. Voila - All jerking gone and a lot more power.
2. It had a BMC airbox fitted with a K&N inside that did not even seal and rattled around inside the box. Also not sealed to the snorkel. I fitted an airbox that I got from Dawid and redid the plumbing. I still need to seal to the snorkel and modify 1 aircon pipe but that is a job for another day.
The concern here was that the vehicle had effectively run without an airfilter for a while but it's saving grace is that it looks like it has not been used offroad much and has no oil trap fitted. This meant that the dust combined with the oil and was left in the turbo, pipes and intercooler but did not make it to the engine.
I am going to recondition the turbo in January as the vanes are pitted and rounded. And I had so much fun cleaning every pipe and the intercooler at Michaels's place.
3. Michael changes the oil and oil filters and the oil is not at all bad for oil that has been in for 10 000 km.
So now everything is off and Michael's job should be easy and he starts by setting the fuel pump timing which was horribly advanced. White smoke from the exhaust which means it is not burning all the fuel.
4. Michael has a set of reconditioned injectors which he fits. Smoke is still white.
5.Michael removes the fuel pump which does not even have a gasket and replaces with a reconditioned fuel pump which he has. Of course the reconditioned fuel pump was set for 1 bar boost and +/- 200 kw so he needs to recalibrate. Black smoke!!!!!!!!
6. While Michael is down there and everything is off the valve clearances are set. 1 was too tight and the rest where too loose.
7. Now everything goes back together as well as fitting the oil temp and water level Madman sensors (It did not have those 2) and Michael will redo a bit of the turbo plumbing which he can elaborate on if he wishes.
So "The Firetruck" should be breathing fire by this evening and we will go steal Tinus's bakkie while he is in Moz so that we can use it as a comparison.
Michael - Please correct or elaborate if necessary.
