Kellaway's Fabia VRS

[kellaway86]

Looks lovely, spotted you parked outside the cop shop this afternoon, very tidy.

Cheers Buddy. I'm in Catterick most days so will keep an eye out for you in your Monte!

[kellaway86]

So been doing a few more bits to the Fabia over the last few weeks.

 

Had new Lemforder track rod ends fitted and tracking re-aligned, didnt bother doing this my self as the garage chucked the track rods on for free with the alignment

 

The old ones where pretty loose and looked original, sorry no pics this time!

 

Next up was the lower ball joint and the fitting PSB Polly Bushes to the lower arm to fully finish off my suspension refresh!

 

Started off with the usual, cleaned the garage out and got the car in and up on stands!

 

IMG_8008.jpg by Daniel Kellaway, on Flickr

 

New Goodies.

 

IMG_8009.jpg by Daniel Kellaway, on Flickr

 

IMG_8010.jpg by Daniel Kellaway, on Flickr

 

IMG_8014.jpg by Daniel Kellaway, on Flickr

 

Old Ball joints, Yum

 

IMG_8016.jpg by Daniel Kellaway, on Flickr

 

Whole arm

 

IMG_8018.jpg by Daniel Kellaway, on Flickr

 

Nut removed with a fight!

 

IMG_8020.jpg by Daniel Kellaway, on Flickr

 

Now, the main lower arm bolt on these is well known to be stuck solid and break off inside of the lower console sub frame, mostly due to the miss match of steel bolt in a aluminium casting. I was fearing the worst so had purchased two new lower consoles from ECP for £117 and some new bolts from TPS in case mine where to break so i wasn't stuck car less.

 

Gave the bolts a good soak in Plus Gas, I've never used Plus Gas before but had heard good reviews and i wasn't disappointed. 

 

So with some praying and a few love taps with the big hammer before i even tried to remove them, i stuck the impact on them and went for it. To my wallets surprise and delight they came flying out! 

 

IMG_8022.jpg by Daniel Kellaway, on Flickr

 

Looks like when the console bushes have been changed in the past the lovely mechanic who did the job gave the bolts a good coat of anti-seize If i could buy that man a beer i would!

 

Grabbed the pickle fork to break the lower ball joint tapers.

 

IMG_8024.jpg by Daniel Kellaway, on Flickr

 

IMG_8026.jpg by Daniel Kellaway, on Flickr

 

Removed from the hub, Ball joint had quite a bit of free play in it on the passengers side.

 

IMG_8027.jpg by Daniel Kellaway, on Flickr

 

After some rotating the arm and some swearing the arm was free.

 

IMG_8028.jpg by Daniel Kellaway, on Flickr

 

In the vice for ball joint removal.

 

IMG_8029.jpg by Daniel Kellaway, on Flickr

 

IMG_8033.jpg by Daniel Kellaway, on Flickr

 

IMG_8034.jpg by Daniel Kellaway, on Flickr

 

Got the drivers side pulled out and found the ball joint was split and very loose.

 

IMG_8035.jpg by Daniel Kellaway, on Flickr

 

IMG_8036.jpg by Daniel Kellaway, on Flickr

 

Now on to removing the front smaller bushings.

 

Cut the excess rubber off then with a combination of m12 threaded road and some sockets push the old bushings out.

 

IMG_8037.jpg by Daniel Kellaway, on Flickr

 

IMG_8038.jpg by Daniel Kellaway, on Flickr

 

IMG_8039.jpg by Daniel Kellaway, on Flickr

 

IMG_8040.jpg by Daniel Kellaway, on Flickr

 

IMG_8041.jpg by Daniel Kellaway, on Flickr

 

IMG_8042.jpg by Daniel Kellaway, on Flickr

 

Both bushes removed and lower arms ready for a quick clean up.

 

IMG_8043.jpg by Daniel Kellaway, on Flickr

 

IMG_8044.jpg by Daniel Kellaway, on Flickr

 

Couple of coats of zinc primer followed by some matt black.

 

IMG_8045.jpg by Daniel Kellaway, on Flickr

[kellaway86]

So the old console bush.

 

IMG_8047.jpg by Daniel Kellaway, on Flickr

 

Removed with a combination of hacksaw and chisels.

 

IMG_8048.jpg by Daniel Kellaway, on Flickr

 

IMG_8049.jpg by Daniel Kellaway, on Flickr

 

IMG_8050.jpg by Daniel Kellaway, on Flickr

 

Old V New

 

IMG_8051.jpg by Daniel Kellaway, on Flickr

 

Tapped in.

 

IMG_8053.jpg by Daniel Kellaway, on Flickr

 

Quick photo of the new track rod ends while im here.

 

IMG_8056.jpg by Daniel Kellaway, on Flickr

 

Arms ready to go.

 

IMG_8057.jpg by Daniel Kellaway, on Flickr

 

Installing the front bush.

 

IMG_8059.jpg by Daniel Kellaway, on Flickr

 

IMG_8060.jpg by Daniel Kellaway, on Flickr

 

IMG_8061.jpg by Daniel Kellaway, on Flickr

 

IMG_8063.jpg by Daniel Kellaway, on Flickr

 

Reinstalling new ball joint.

 

IMG_8065.jpg by Daniel Kellaway, on Flickr

 

IMG_8067.jpg by Daniel Kellaway, on Flickr

 

Ready to go.

 

IMG_8068.jpg by Daniel Kellaway, on Flickr

 

New M12 bolts.

 

IMG_8069.jpg by Daniel Kellaway, on Flickr

 

After some fighting and swearing got the lowers arms back in and bolted up. Took some hammering and aligning but got the job sorted.

 

IMG_8070.jpg by Daniel Kellaway, on Flickr

 

IMG_8072.jpg by Daniel Kellaway, on Flickr

 

IMG_8073.jpg by Daniel Kellaway, on Flickr

 

Got the wheels back on and went for a drive, massive improvement yet again. Alot more precise turn in and not as much wondering around on the road! Well worth the time and money!

[tonysandberg]

Nice job, will be doing the same on my when its time for winter tyres.

[skodalad]

Nice attention to detail there pal

[hutchysrs50]

I've got to say, im surprised someone like you didnt just replace the bottom arms, i picked up two new arms with ball joints and bushes for £40 on ebay, since you were replacing the bushes anyway it wouldnt have made much difference.

[kellaway86]

I've got to say, im surprised someone like you didnt just replace the bottom arms, i picked up two new arms with ball joints and bushes for £40 on ebay, since you were replacing the bushes anyway it wouldnt have made much difference.

Ive been burned in the past with cheap lower arms. I was on the look out for some febi or lemforder arms to pop up for a reasonable price but couldnt find any. Wanted to polly bush the whole arm. Hopefully going about it this way i wont have to change the ball joints again.

[hutchysrs50]

The ones i got were Febi, so i was pleased! very lucky to get them mind.

[kellaway86]

Small update, been trouble free motoring for the last few thousands miles, just general keeping the VRS clean and getting out and using it!

 

As the cold nights started coming in i noticed the battery becoming ever so weak, considering its the original battery at 9 years old its time for a change!

 

New Exide EA640 4 Year warrenty 64Ah with 640CCA! - £48 delivered next day bargain! Euro Car Parts wanted over £75 for the same battery!

 

IMG_8461.jpg by Daniel Kellaway, on Flickr

 

Whipped the old one out in the freezing cold due to my garage having a family members car in for repair!

 

IMG_8462.jpg by Daniel Kellaway, on Flickr

 

9 Year old original!

 

IMG_8463.jpg by Daniel Kellaway, on Flickr

 

Installed in its new home!

 

IMG_8465.jpg by Daniel Kellaway, on Flickr

 

Jumped in the car and wow, i hadn't really noticed how bad the old battery had got! Engine jumped to life extremely fast!

 

Should see me right for winter!

[Lofty]

Great updates! Keep them coming

[hutchysrs50]

Thats what i thought when i replaced mine, it actually transformed the car when starting on cold mornings.

No more sluggish turning over with a puff of smoke out the back, just turn the key and get an instant start.

[kellaway86]

Thats what i thought when i replaced mine, it actually transformed the car when starting on cold mornings.

No more sluggish turning over with a puff of smoke out the back, just turn the key and get an instant start.

Yup, mine was starting to get very smokey on start up and it's now as clean as a whistle. Yup it's crazy how fast they start with a new battery!

[kellaway86]

So been 12k miles and a year of motoring out of the VRS, she is due for an MOT and service.

 

IMG_0415.jpg by Daniel Kellaway, on Flickr

 

So took her down the local Mot place, and she passed! however not with a clean sheet!

 

IMG_0412.jpg by Daniel Kellaway, on Flickr

 

The tyres are going to be a easy fix, knew they were getting low.

 

The Cv Boot was not expected, and its getting sorted ASAP. Dont want water and crap getting in the joint!

 

The only oil leak ive been able to find is the lower inter cooler pipes have a slight weep on them. Noting to worry about and a quick clean will be fine.

 

The exhaust clamp, yet again. Easy Fix.

 

So went and grabbed some parts!

 

IMG_0408.jpg by Daniel Kellaway, on Flickr

 

IMG_0429.jpg by Daniel Kellaway, on Flickr

 

IMG_0430.jpg by Daniel Kellaway, on Flickr

 

Then got her home and in the garage and up on axle stands!

 

IMG_0418.jpg by Daniel Kellaway, on Flickr

 

First up was oil and filter change!

 

IMG_0420.jpg by Daniel Kellaway, on Flickr

 

IMG_0421.jpg by Daniel Kellaway, on Flickr

 

IMG_0423.jpg by Daniel Kellaway, on Flickr

 

Then air,

 

IMG_0432.jpg by Daniel Kellaway, on Flickr

 

IMG_0434.jpg by Daniel Kellaway, on Flickr

 

Pollen filter, which wasnt to bad to be honest, but changed anyway.

 

IMG_0435.jpg by Daniel Kellaway, on Flickr

 

IMG_0436.jpg by Daniel Kellaway, on Flickr

 

Sorted the exhaust clamp, was past its best haha!

 

IMG_0439.jpg by Daniel Kellaway, on Flickr

 

IMG_0442.jpg by Daniel Kellaway, on Flickr

 

Replaced with a new ECP special!

 

IMG_0444.jpg by Daniel Kellaway, on Flickr

 

 

Going to sort the CV boot over the weekend, just waiting on a 36mm 12pt Bi-Hex socket to be delivered off Amazon. I've got a pretty decent selection of tools, but always seem to need more :D

Edited 12 January, 2017 by kellaway86

[kellaway86]

CV Boot Fix Part 1

 

So decided to go get a genuine CV Boot so nipped to TPS and picked up one, and took the other one back to ECP, Not worth the risk of having to do the job twice!

 

IMG_0445.jpg by Daniel Kellaway, on Flickr

 

Also got a new 36mm 12 point socket from amazon for the hub nut!

 

IMG_0446.jpg by Daniel Kellaway, on Flickr

 

IMG_0447.jpg by Daniel Kellaway, on Flickr

 

So got "my assistant " to hold the break for me while undoing!

 

IMG_0450.jpg by Daniel Kellaway, on Flickr

 

Once that's removed next is the 3 x 13mm bottom ball joint bolts!

 

IMG_0454.jpg by Daniel Kellaway, on Flickr

 

Next up the 6 x M12 spline bolts on the drive shaft, easy removal with the air ratchet!

 

IMG_0457.jpg by Daniel Kellaway, on Flickr

 

Give the shaft a knock or two and you have your self 1 x driveshaft!

 

IMG_0459.jpg by Daniel Kellaway, on Flickr

 

Split boot.

 

IMG_0461.jpg by Daniel Kellaway, on Flickr

 

Cut the boot open and put some gloves on! Its going to get messy!

 

IMG_0464.jpg by Daniel Kellaway, on Flickr

 

Yummy 

 

IMG_0465.jpg by Daniel Kellaway, on Flickr

 

IMG_0466.jpg by Daniel Kellaway, on Flickr

 

After using an entire roll of paper towel.

 

IMG_0467.jpg by Daniel Kellaway, on Flickr

 

Proceed to knock the knuckle off the shaft! Lump hammer required here as the ball peen not man enough!

 

IMG_0468.jpg by Daniel Kellaway, on Flickr

 

Knuckle Removed.

 

IMG_0469.jpg by Daniel Kellaway, on Flickr

 

IMG_0472.jpg by Daniel Kellaway, on Flickr

 

Given a proper clean.

 

IMG_0473.jpg by Daniel Kellaway, on Flickr

 

Cleaned up with the wire wheel and masked for painting!

 

IMG_0475.jpg by Daniel Kellaway, on Flickr

 

Primer then top coat!

 

IMG_0479.jpg by Daniel Kellaway, on Flickr

 

Leaving that to dry over night and will put it back together tomorrow!

 

 

 

 

[kellaway86]

EGR Delete / Blank / Manifold Clean

 

So Ive decided to blank off the EGR and give the inlet and ASV a good clean. Im sure its due after 125k miles!

 

BLT Engine EGR Setup

 

IMG_0480.jpg by Daniel Kellaway, on Flickr

 

Remove the elbow,

 

IMG_0483.jpg by Daniel Kellaway, on Flickr

 

Sign of things to follow, ASV looking "clean"

 

IMG_0482.jpg by Daniel Kellaway, on Flickr

 

ASV removal

 

IMG_0485.jpg by Daniel Kellaway, on Flickr

 

Some nice pesky hidden bolts!

 

IMG_0486.jpg by Daniel Kellaway, on Flickr

 

O boy! The ASV!!

 

IMG_0492.jpg by Daniel Kellaway, on Flickr

 

IMG_0493.jpg by Daniel Kellaway, on Flickr

 

The EGR!!

 

IMG_0498.jpg by Daniel Kellaway, on Flickr

 

Inlet not looking the best!

 

IMG_0500.jpg by Daniel Kellaway, on Flickr

 

Turbo Inlet Pipe removed!

 

IMG_0502.jpg by Daniel Kellaway, on Flickr

 

BLT Euro 4 EGR Cooler removal! Had some right pain in the ass bolts to remove!

 

IMG_0504.jpg by Daniel Kellaway, on Flickr

 

Finally the Inlet manifold removed!

 

IMG_0506.jpg by Daniel Kellaway, on Flickr

 

IMG_0510.jpg by Daniel Kellaway, on Flickr

 

Bit Choked up!

 

IMG_0511.jpg by Daniel Kellaway, on Flickr

 

Next drained the coolant so i can remove the EGR Cooler!

 

IMG_0512.jpg by Daniel Kellaway, on Flickr

 

IMG_0515.jpg by Daniel Kellaway, on Flickr

 

Then take out on of the coolant pipes and loop it into the "T" to complete the circuit!

 

IMG_0516.jpg by Daniel Kellaway, on Flickr

 

IMG_0517.jpg by Daniel Kellaway, on Flickr

 

That's as far as i got tonight, blanking plates should be here tomorrow, and already picked up new gaskets and O rings from TPS. 

 

Going to be doing a bit of DIY ECU tinkering as well as blanking the EGR will throw the EML on.

 

Think she going to drive alot better with all that crap cleaned out!

 

 

 

 

[kellaway86]

Got a bit more work completed today before work.

 

Decided to tackle all the dirty jobs today and get every thing cleaned up ready to go back together.

 

All started with fire!

 

IMG_0518.jpg by Daniel Kellaway, on Flickr

 

A very dirty inlet about to get a good "bath"

 

IMG_0521.jpg by Daniel Kellaway, on Flickr

 

IMG_0520.jpg by Daniel Kellaway, on Flickr

 

Fire + compressed air = Clean manifold!

 

Here is the Youtube video of it on fire :D https://youtu.be/7yy7m6XdkkI

 

burn1.jpg by Daniel Kellaway, on Flickr

 

burn2.jpg by Daniel Kellaway, on Flickr

 

After burning, some dry carbon remains.

 

IMG_0525.jpg by Daniel Kellaway, on Flickr

 

IMG_0527.jpg by Daniel Kellaway, on Flickr

 

Got the Egr and ASV cleaned out, with a combination of chemicals and scrubbing! 

 

IMG_0532.jpg by Daniel Kellaway, on Flickr

 

IMG_0533.jpg by Daniel Kellaway, on Flickr

 

IMG_0535.jpg by Daniel Kellaway, on Flickr

 

IMG_0536.jpg by Daniel Kellaway, on Flickr

 

Set about giving the manifold and the turbo inlet pipe a good clean!

 

The finished product!

 

IMG_0540.jpg by Daniel Kellaway, on Flickr

 

IMG_0542.jpg by Daniel Kellaway, on Flickr

 

IMG_0544.jpg by Daniel Kellaway, on Flickr

 

IMG_0545.jpg by Daniel Kellaway, on Flickr

 

IMG_0546.jpg by Daniel Kellaway, on Flickr

 

Next moved onto sorting the CV Boot

 

Unmasked.

 

IMG_0537.jpg by Daniel Kellaway, on Flickr

 

New boot on,

 

IMG_0550.jpg by Daniel Kellaway, on Flickr

 

No pictures of the during, didn't want to get new CV grease all over the place!

 

IMG_0553.jpg by Daniel Kellaway, on Flickr

 

Next dirty job was change the leaking rocker cover gasket, it had been seeping down the back of the engine.

 

IMG_0554.jpg by Daniel Kellaway, on Flickr

 

Removed

 

IMG_0556.jpg by Daniel Kellaway, on Flickr

 

Here is where it had been leaking.

 

IMG_0561.jpg by Daniel Kellaway, on Flickr

 

And here,

 

IMG_0562.jpg by Daniel Kellaway, on Flickr

 

New one getting put in place, not many pics as you have to use some sealant! You use a couple of spots of sealant and then place the cover back on the head them torque down the 13 bolts in a pattern to 10NM.

 

Cambelt looked in good condition!

 

IMG_0564.jpg by Daniel Kellaway, on Flickr

 

Thats it for today, got the rocker cover back on, and cleaned up the massive mess i had made. Hopefully next few days will get it all put back together!

Edited 17 January, 2017 by kellaway86

[hutchysrs50]

Good updates as usual.

The BLT EGR valve setup is a right chew to remove isn't it :D

As for the carbon build up, it's just like have restrictor plates fitting across the inlet manifold! Much better to get them removed.

[kellaway86]

The EGR/ASV wasn't as bad to remove as i was expecting, it was the god damn EGR Cooler that i wanted to smash up with a hammer! Yer once its back together its got to run alot better without all that crap restricting airflow!

[coskev]

Great job :)

Love the flaming of the inlet! Where did you get that idea?

One thing I would have done whilst cam cover/EGR was off is bang in a set of PD150 headbolts

[kellaway86]

Seen the flaming of the inlet on youtube, works a absolute treat!

 

Update.

 

So the EGR blanking plates finally got delivered, some nice 3mm think ones with new gaskets. 

 

IMG_0565.jpg by Daniel Kellaway, on Flickr

 

Blanking the manifold end.

 

IMG_0567.jpg by Daniel Kellaway, on Flickr

 

IMG_0568.jpg by Daniel Kellaway, on Flickr

 

Then the EGR End. Had to use new M6 bolts with some extra nuts and spacers to take the slack.

 

IMG_0571.jpg by Daniel Kellaway, on Flickr

 

IMG_0572.jpg by Daniel Kellaway, on Flickr

 

Next up was replace the Inlet manifold, new genuine gasket used.

 

IMG_0579.jpg by Daniel Kellaway, on Flickr

 

Installed, looking alot cleaner!

 

IMG_0583.jpg by Daniel Kellaway, on Flickr

 

Next up turbo intake pipe.

 

IMG_0585.jpg by Daniel Kellaway, on Flickr

 

Had to use a jubilee clip instead of the spring clip as it was in a nightmare location!

 

Installed.

 

IMG_0587.jpg by Daniel Kellaway, on Flickr

 

Got all the EGR and ASV bolted back on and the boot pipes reinstalled.

 

IMG_0588.jpg by Daniel Kellaway, on Flickr

 

Next up was just the quick job of putting the driveshaft back in.

 

First off get the driveshaft back in the hub and re tighten the lower wishbone bolts.

 

IMG_0573.jpg by Daniel Kellaway, on Flickr

 

New nut a must.

 

IMG_0576.jpg by Daniel Kellaway, on Flickr

 

Tightened to 70NM then 45 degrees = tight!

 

IMG_0577.jpg by Daniel Kellaway, on Flickr

 

Jack up lower arm to enable you to install the remaining 6 spline bolts dune up and torqued to spec.

 

Finished, no more nackard CV Boot.

 

IMG_0578.jpg by Daniel Kellaway, on Flickr

 

 

So got the engine undertray back on and topped the fluids back up and went for a drive!

 

WHAT A DIFFERENCE!! So much more responsive and feels so much smoother! 

 

How ever as expected, the EML is now on in the dash. Will be sorting that in the next update!

Edited 21 January, 2017 by kellaway86

[hutchysrs50]

Not sure the paper gasket on the turbo end will last very long, should be the metal gasket iirc!

Good work again though :thumbup:

[kellaway86]

Yer, will keep an eye on the paper gasket!

 

Engine Management Light - The Fix.

 

IMG_0589.jpg by Daniel Kellaway, on Flickr

 

So after a lot of research i dragged my computer down to the garage, got the car pulled in hooked up via a cheap Chinese MPPS cable!

 

IMG_0595.jpg by Daniel Kellaway, on Flickr

 

IMG_0610.jpg by Daniel Kellaway, on Flickr

 

Fired up the MPPS software and it connected right away.

 

IMG_0597.jpg by Daniel Kellaway, on Flickr

 

Downloading a copy of the cars map.

 

IMG_0600.jpg by Daniel Kellaway, on Flickr

 

Little bit sketchy i know!

 

IMG_0601.jpg by Daniel Kellaway, on Flickr

 

Once it had finished downloading the map, i set about editing the EGR codeblock.

 

IMG_0602.jpg by Daniel Kellaway, on Flickr

 

The theory here is to flatten the block so the ECU is not longer requiring the air flow that the EGR would have been adding.

 

IMG_0604.jpg by Daniel Kellaway, on Flickr

 

Once that was sorted, you save the map ready for re-flashing to the car.....

 

The scary, no going back question!

 

IMG_0606.jpg by Daniel Kellaway, on Flickr

 

Followed by 3mins of terror, hoping not to brick the ECU!

 

IMG_0608.jpg by Daniel Kellaway, on Flickr

 

Pleased to report that the flash went fine and the car jumped to life!

 

Last job was to clear the DTC code for the EGR via VCDS.

 

IMG_0612.jpg by Daniel Kellaway, on Flickr

 

With the fault cleared, it was time for a test drive!

 

Im very pleased to report that after 20miles the EML has not returned! So bit of DIY mapping success! 

[hutchysrs50]

Now that is quite impressive really!

I've got the software but never attempted to mess around with the mapping, good little guide you've put up really :D

I'd like to try that on my MK2 as the light has came on since blocking the EGR valve, sadly I think my ECU needs to be removed and modified in some way before you can edit the software

[Richard92]

Now that is quite impressive really!

I've got the software but never attempted to mess around with the mapping, good little guide you've put up really :D

I'd like to try that on my MK2 as the light has came on since blocking the EGR valve, sadly I think my ECU needs to be removed and modified in some way before you can edit the software

Just looked online for this and it doesn't support the Mk 2 with the 1.6 tdi? I will keep looking as I'd love it off for egr too.

Very impressed with DIY mapping. Well done sir !!

Edited 23 January, 2017 by Richard92

[hutchysrs50]

Just looked online for this and it doesn't support the Mk 2 with the 1.6 tdi ???????? I will keep looking as I'd love it off for egr too.

Very impressed with DIY mapping. Well done sir !!

Sadly not, the ECUs are locked really...

One of the downsides to newer software I guess! It hasn't been messed around with as much.