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Model specific boards => Golf mk3 => Golf mk3 gallery => Topic started by: jv on 25 February 2015, 13:36

Title: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: jv on 25 February 2015, 13:36
:)
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 25 February 2015, 16:39
Thank you...feel like I'm in the spotlight now  :grin:

Right, here is my little project.. I've no clue what I'm doing, I have a Haynes manual..tools....and you lot..and I trust you guys...a lot..don't let me down...

Some of you in the Mk3 section have been bored to tears about my Golf Cabrio Avantgarde 2.0 8v Auto,

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg1.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg1.jpg.html)

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg2.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg2.jpg.html)



I bought it for £310 off ebay, the gearbox is knackered, it stalls in drive and reverse from cold, when warm, it almost kills you by launching forward or backward, when it does sort itself out, it goes from 1st to 2nd fine, it jolts into 3rd then slips, revs high, makes a squealing sound, then jolts into 4th, (good job the seat belts work!!) and does the same,

Bodywork is fine, just needs some TLC, roof has a slight split that doesn't leak...yet

(http://i107.photobucket.com/albums/m318/hardmonkeys/Golf%20Cabrio/CA2DECA4-270C-4A92-88CF-C396A997087D.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/Golf%20Cabrio/CA2DECA4-270C-4A92-88CF-C396A997087D.jpg.html)

(http://i107.photobucket.com/albums/m318/hardmonkeys/Golf%20Cabrio/4AE001F1-7930-4944-AB4E-FDF3224B8C9B.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/Golf%20Cabrio/4AE001F1-7930-4944-AB4E-FDF3224B8C9B.jpg.html)

It just needs some TLC, all over..

Engine runs lovely, slight oil leak from rocker, but nothing that can't be sorted...
Interior was grubby, previous owner basically didn't care once the gearbox threw a wobbly, pay and display tickets, crisp packets and hadnt been hoovered for a while

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg3.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg3.jpg.html)

So!! I've tried to fix this gearbox problem, either by fixing it, or replacing it...I put a few requests on the various savage sites..1st part breaker etc etc, all I got was

Quote for your 2.0 VW Golf AvantGarde Reconditioned Auto Gearbox with TorqueConverter, can Supply zero mileage and Fully Fit for £1595; comes with a 2year unlimited mileage warranty and diagnostics.            Kind Regards. www.jbecompany.com. Please contact 07********* to book in; or with any queries or questions you may have, thank you.

Cost.....a WHOPPING £1650  :shocked: :shocked: :sick:

Look on eBay, AGG engine and auto box...£440, I ring the guy, ask if it runs..well...basically does it work, couldn't 100% say it did, it might of he said, so I decided to keep looking, I can hear the missus saying  :grin: :grin: :grin: ' i told you so

Now, as i was looking I went through the idea of swapping the engine..really wanted to go VR6...but didn't wanna spend to much on one, then break it, seems a waste, so toyed with the idea of converting to manual, I'm not a mechanic, but think I know my way around a car..I did 2yrs (ish) at college doing a city and guilds in Light Vehicle Mechanics, but that was 12yrs ago now, possibly longer.

I read through the Haynes (they make it sound easy!!) i understood the jargon, so figures I'd give it a go, I decidedmto buy a donor car, as all the bits will be there, rather than buying bits and pieces and then realising I need the other bit,

So after a few days of searching for a mk3 with minimum 2.0 8v engine and manual box, I found this,

(http://i107.photobucket.com/albums/m318/hardmonkeys/Golf%20Cabrio/29C135DC-C069-4E3D-ACF1-9A0D1B0BEBD1.png) (http://s107.photobucket.com/user/hardmonkeys/media/Golf%20Cabrio/29C135DC-C069-4E3D-ACF1-9A0D1B0BEBD1.png.html)

(http://i107.photobucket.com/albums/m318/hardmonkeys/Golf%20Cabrio/3BB2CBA7-0026-43C0-9241-A35C24A769A1.png) (http://s107.photobucket.com/user/hardmonkeys/media/Golf%20Cabrio/3BB2CBA7-0026-43C0-9241-A35C24A769A1.png.html)
(http://i107.photobucket.com/albums/m318/hardmonkeys/Golf%20Cabrio/13D24DD8-5DC0-44B2-84C7-A01997C5F706.png) (http://s107.photobucket.com/user/hardmonkeys/media/Golf%20Cabrio/13D24DD8-5DC0-44B2-84C7-A01997C5F706.png.html)

Cost me £260 off ebay, it's a Golf GTi with 2.0 16v (ABF) lump and manual box, 132k, full service history and receipts, 12 1/2mths mot! Drove it 70miles home, it's sweet as!! The bodywork is a little tatty, and there are a few rust issues..but it's the engine I was interested in.

This project is going to be a slow burner, I have no idea what I'm doing, but with a little research and I fo from you, I'm gonna make this a good one, hopefully!!

Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 13 March 2015, 11:28
Booked the time off work, so 18th April onwards is the week it WILL be done!

Previous owner of the gti has found all the receipts for all the work he had done and sent them on.

Can't wait to get cracking now!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 18 April 2015, 07:31
So...here we go! The time has come, make or break (literally)...

Just got the small matter of last day at work to do before I can start this. Pictures later!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 19 April 2015, 09:38
Well I got started at around 1pm yesterday, started to strip out the Cabrio to get to the auto ecu and loom and also stripping out the dash to swap the pedal boxes, I really should of researched it a bit more if it honest, I didn't realise it was such a big job, still, in for a penny in for a pound, I've started so I'll finish.


(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg3_2.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg3_2.jpg.html)

Pictures of the half stripped dash.


(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg1_5.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg1_5.jpg.html)

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg2_3.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg2_3.jpg.html)

Crud from under the scuttle!

I'm going to be giving this a good clean before it all goes back together

I've had some help from madmanmart off of here, through text,  he has been a a godsend, a wealth of information

Today is going to be much of the same, as all of the manual stuff needs to be removed from the GTi, so that's where my day lies, after I finish work(why did I volunteer I do not know!!!) engine hoist being delivered tomorrow, so hopefully I'll be starting to prepare for that soon enough.

I hope this Weather stays for the time I've got off it reall is helping a lot.

Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 19 April 2015, 21:11
Well, today didn't go as planned, I didn't even start the GTi strip down, the Cabrio has tested me today,

I had to remove the steering column today to get to pedal box, everything was going ok, until I met the shear bolts, when tightened at the factory, the head snaps..so you can't remove them...using some handy advice from madmanmart, I used a  chisel and hammer, to knock it round, 1st one came out ok, the other....well...it took an hour of chiseling, drilling, sawing...and swearing!!

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg1_6.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg1_6.jpg.html)

It finally came out!!

I then had to remove the steering column from the intermediate shaft, this confused me as I couldn't see where this was, after removing the connecting plate,  and smashing my knuckles off the fascia mounts it came free, out came the column

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg2_4.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg2_4.jpg.html)

Then it came to whipping the dash out, oh yeh it was soooo easy!! NOT!! It took me a while to make sure it was all free and loose before I removed it, had to label all the wires, so not to forget what goes where, there is an alarm that has been fitted...not sure if at factory or dealer fit, as its VW marked, but the wires are all over the place, and some of the plastics behind the fascia are cracked, whoever did it wasn't that great at their job!

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg4_2.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg4_2.jpg.html)

But it finally came out, this is where it's left, as I need to now strip the GTi, which is a job for tomorrow, the engine hoist is coming tomorrow so then it all systems go
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 20 April 2015, 12:47
Removed the dash from the GTi!!! So now we are stuck in!!

Engine removal now!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 23 April 2015, 11:02
Hey, I've finally got the 8v out the cabrio, it was a bit of job for novice like me, but my excuse is I have done it all on my own, none of the 'mates' that have said they'd be round to help have shown their faces...obviously under the thumb of the missus haha

Anyways,


(http://i107.photobucket.com/albums/m318/hardmonkeys/Mobile%20Uploads/image_2.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/Mobile%20Uploads/image_2.jpg.html)

I throughly enjoyed it, despite going in completely blind! The gti is almost ready to have its engine removed, just a few little things to remove, then its out and ready to be transplanted, I'm going to clean it up when it's out and also scrub up the bay of the Cabrio,

Next jobs:-

to completely remove the engine from the gti
Remove the looms from the cabrio and replace with the looms from the gti
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: mjb on 23 April 2015, 21:08
Nice work
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 23 April 2015, 22:22
It's going ok, I've lost a day today tho, my little one was admitted into hospital today, so I'm up here with her tonight,
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 25 April 2015, 10:19
Finally getting back on this today, my little one is now out of hospital after 2 days.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 26 April 2015, 20:01
Finally got back into this, not as quick as I would of like as I'm having to still take my daughter up the hospital every day, for her meds, still managed to get the engine out of the 16v

(http://i107.photobucket.com/albums/m318/hardmonkeys/FC79F569-5AC8-4CCF-BD13-D972D1C94C24.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/FC79F569-5AC8-4CCF-BD13-D972D1C94C24.jpg.html)

I had a few stubborn bolts, as expected, on the cat-downpipe flange, so I got my junior hacksaw (don't laugh lol) out and got to work, hour or so later, it was done!!  :laugh: :laugh:

Next stage was the easy bit, strap her up, and release her mount bolts!

Quite happy with the way this has gone so far, having not took an engine out of a car for 12 yrs, I've took 2 out in 5 days! Happy with this progress!

Unfortunately I'm back to work on Tuesday. So can't do much in the week, I work odd shifts so normally in bed by 7pm

I hope to get dribs and drabs done in the evening, and full weekends over the next few weeks

Next jobs:-

Sort and swap looms over
Change pedal boxes
Possible swap running gear although not sure about this yet.

Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 27 April 2015, 12:03
Just a quick update

Removed the loom from the Cab today, just to sort through this little lot

(http://i107.photobucket.com/albums/m318/hardmonkeys/D7BF4FA0-DA4D-44C8-A57E-F92BC322BB05.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/D7BF4FA0-DA4D-44C8-A57E-F92BC322BB05.jpg.html)

to remove it from the fusebox...wish me luck!!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 07 May 2015, 20:41
Not been on here for a while, worked all through the bank holiday weekend, I managed to sort through the looms on both cars, and remove them, ABF loom was easier, obviously I knew which plugs from the fusebox to remove this time, and sort through them if any were different,

I've had to swap the whole immobiliser from the gti over to the cab, I was hoping to get away with just swapping the chips in the keys, but the immobiliser connections were different, also the immobiliser ring that goes over the ignition barrel was different, sorted through that little lot, again with the tx line of MadmanMart from on here...again Very knowledgable, I wouldn't of had a clue if it wasn't for him.

I've completely removed the automatice gearbox loom from the cab, geez this took some time, it comes through the bulkhead with the ABS loom, and goes back to under the rear seats, to the auto gear selector, up under the dash, and over to the fusebox, I got halfway through and thought I'd made a error, and cut the wrong wires....luckily I don't think I have....(yet to find out.....officially)

I've replaced then power steering pipe to the power Steering pump as I snapped..(read strapped!!! It up with the engine) it when removing then AGG! So I removed it from the GTi and put it on the Cabrio, fiddly little bastard...19mm long spanner, but had to remove another before I could get to the one I needed, then had to put it all back together again, in the relevant clips and making sure the pipe aren't rubbing.

I've removed the auto gear selector from the Cabrio and the manual from the GTi and swapped them, of course this involved removing the whole exhaust systems from both cars, it's a miracle I've still a mouth full of teeth, never realised how heavy they are when on ya back!

So I've been a busy bugger these last few weeks, I still haven't finished yet!

Hopefully this weekend I'll be closer to getting that engine in the Cabrio and it running!!!

Fingers crossed!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 07 May 2015, 20:47
Almost forgot I removed the pedal boxes from the cars, I broke the big white clip on the back of the brake pedal, ordered a new one from VW £7.39!!!

It's all ready for the weekend :-)
Title: ITS IN!!
Post by: hardmonkeys on 14 May 2015, 18:29
(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg1_9.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg1_9.jpg.html)

Its in!! Went in really easily if I'm honest, expected a few little issues but none were present!

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg2_7.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg2_7.jpg.html)

I've refilled with coolant, after buying a new expansion tank as the original and the GTi ones were caked in a clay like substance, not good if it got into the system.

 :laugh: :laugh: :laugh: AND IT RUNS!!!!!  :grin: :grin: :grin:

Feeling very proud of myself, I have never done anything like this before, so it's kinda of a big deal!

After I got over myself :huh:  I was giving it all the once over, running it up to temp, I noticed a split in the (now prone to go I've found out) oil breather pipe in the front of the engine

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg1_8.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg1_8.jpg.html)

I went to up the local dealers to see about getting a new pipe, after finally explaining to the parts guy which pipe it was, he duly told me VW stopped making it 18mths ago!! And didn't supersede it with anything.....GREAT!!

So online I went, thinking someone must have one, yes...someone did. VW parts international...for £29.49!!!  :sick: lot of money for a pipe! But a lot of man hours have gone into this, so I didn't want to leave it. It arrived today, and will be fitted this weekend probably

Next jobs:-

I've decided to go 5x100 so got to remove the hubs and driveshafts from the GTi and swap to the cab
Connect steering

GO FOR A DRIVE!!!


Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 25 July 2015, 11:54
Has it really been that long since I updated this!! Geez

Right, so after removing the running gear from the GTI and fitting to the cab, I changed all the wishbones and drop links for new, as they weren't looking too great, I was all too excited about getting it moving under its own power...big mistake, I managed to break driveshaft, it popped out of the hub and I hadn't noticed until I dropped it down onto the ground...and moved it...WHAT A NOISE!!

So I had to get a second hand one at eBay, i think it cost around £30 which wasn't too bad, when it came through ( I was on holiday!!!) I carefully fitted it, and carefully dropped it down.

IT MOVES!!

Works in all gears, brakes need some work though, so that's the next job, I think it most probably has a big airlock in the system as they go spongy very quickly after bleeding, something to do when the weather changes for the worst..

I've also changed the cv boot on the n/s as it was perished and split during fitting.

I've not done much to be recently as we've been on holiday, and the missus got a new car that needed some work doing, and I've just been enjoying some family time during the summer months, a lot of people have said I need to get it running and working before the summer ends, but there is always next summer, I do have a lot to do still, I need to wire the lights up, refit the dash and interior.

So I'm taking my time
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 23 August 2015, 21:42
i've found a new problem to sort, i hadn't mention before than i broke a driveshaft, while getting over excited about driving it, i hadn't noticed it had slipped out of its joint..so when i went to drive it, it made a crunching noise and that was the end of that lol...so...i attempted to remove the joint from the hub, it was jammed solid,tried to get someone to press it out, but they couldnt, so i found a new hub and shaft on ebay off a GTI for about £40

when it came through i got straight onto it that weekend while the weather was on my side, removed the hub, removed the broken shaft, then refitted the replacement parts, tighten and torqued, wheel back on, all was grand....until i went to move the car again...there was a rubbing sound, took me aged to figure out what it was..

(http://i107.photobucket.com/albums/m318/hardmonkeys/Mobile%20Uploads/image_5.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/Mobile%20Uploads/image_5.jpg.html)

The Caliper was rubbing against the wheel, which it wasn't before, so i think the hub is the incorrect one...annoying!

so back to the drawing board, i'm going to reattempt to get the old joint out the old hub..hopefully this will happen, and ill be putting that back on
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 15 September 2015, 08:54
Managed to sort the caliper, I'd failed to put the springs on the caliper over the carrier to  pull it towards each other..school boy error

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg3_6.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg3_6.jpg.html)
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 16 September 2015, 15:44
I'd finished sorting the engine bay wiring out, and figured I'd need to attempt to rewire the headlights back up, as most know the mk3 and mk4 plugs are different

MK3 connector

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg1_12.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg1_12.jpg.html)


MK4 connector

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg2_10.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg2_10.jpg.html)


The mk3 has its own lighting wiring loom, that connects to the main ABF loom with a twist plug, something like this

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg1_13.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg1_13.jpg.html)

Whereas the mk4 was incorporated within the AGG loom



The main problem was, with me not being used to reading wiring diagrams, I was afraid I'd mess it up...4 hrs later..and we have light

(http://i107.photobucket.com/albums/m318/hardmonkeys/25B6CCFF-E3A1-41F4-A785-67DB34082EFF.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/25B6CCFF-E3A1-41F4-A785-67DB34082EFF.jpg.html)


And back on
(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg1_15.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg1_15.jpg.html)

I looked back this weekend just gone...and figured I'm almost ready for rebuilding it...

I hope lol

So...here I go..

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg1_16.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg1_16.jpg.html)
...

I went through every wire, I nudged, pulled, cut, split, and reconnected, to double check I'd done everything correctly, and to ensure it was all weatherproof.

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg4_5.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg4_5.jpg.html)

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg6_2.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg6_2.jpg.html)

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg5_3.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg5_3.jpg.html)

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg7_2.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg7_2.jpg.html)

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg9_1.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg9_1.jpg.html)

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg10_1.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg10_1.jpg.html)


Dash all in, now to put the interior in.




Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 16 September 2015, 15:53
Front seats in

(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg14_1.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg14_1.jpg.html)

Rear seats and windbreaker
(http://i107.photobucket.com/albums/m318/hardmonkeys/image.jpg15_1.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/image.jpg15_1.jpg.html)
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 11 October 2015, 09:06
Had a little setback yesterday,

Got in the Golf, battery flat, managed to roll it down a hill and attempt to bump start it...didn't work, smoke coming up from under scuttle, jumped out and managed to disconnect the battery (luckily had some tools in the boot)

(http://i107.photobucket.com/albums/m318/hardmonkeys/image_3.jpeg) (http://s107.photobucket.com/user/hardmonkeys/media/image_3.jpeg.html)

This is what I'm left with! Something has obviously drained then battery, and as I've got to start it, it caused the surge somewhere...I'm not 100% on how much of the loom is affected yet, and as a result, still unsure if it can be fixed easily, or a replacement loom is the best route...
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 13 October 2015, 18:24
Stripped back the insulation to see how badly damaged the loom was,

(http://i107.photobucket.com/albums/m318/hardmonkeys/image_7.jpeg) (http://s107.photobucket.com/user/hardmonkeys/media/image_7.jpeg.html)

(http://i107.photobucket.com/albums/m318/hardmonkeys/image_6.jpeg) (http://s107.photobucket.com/user/hardmonkeys/media/image_6.jpeg.html)

As you can see, it's not great!

New loom it seems, might see about repairing it, if it's possible.

Title: Replacing the burnt out loom....
Post by: hardmonkeys on 18 October 2015, 16:32
So...I had a sparky come out to the car, have a look at the damage to the loom, and he has adviced it is better to replace the whole loom, rather than repair it...so..out comes the engine again!!

 :sick:

Engine and engine bay clean coming up aswell...figured I may as well take the oppuntunity whilst it's empty
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 25 October 2015, 16:51
Possibly got a loom on its way... :smiley:  :cool:

watch this space :laugh:
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 29 December 2015, 19:30
Ordered my engine hoist..so should be starting to sort this in the new year  :smiley: :smiley:
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 30 December 2015, 03:56
Bit of an update,

The loom fried itself back in October, partly my fault, I'd put the (-) lead from the battery down to the starter, this caused the starter to try to earth through the main loom, I was lucky I didn't kill it sooner, so...its sat in the garage since October, and over the last few months, I've got a new loom, and I've ordered a engine hoist, it seemed daft hire another one again.

So in the new year the engine will be back out again..and the loom changed, I'm sure there will be more problems to come  :grin:
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 10 February 2016, 16:29
Pulled the car out the garage to have tidy around the car, got rid of a of junk collected over the Xmas and new year period..

My drivers window is stuck open, from when I try to jump start the car back in October, which means I can't leave the car out the garage at the minute...slightly annoying as I need the room in the garage. I tried to connect the battery back up and quickly do the Window up, but the loom started to smoke again, so quickly aborted that...

Update soon
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: jimmydub on 10 February 2016, 17:50
This makes for a heartbreaking read! Will be following your progress mate, good luck!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 10 February 2016, 17:58
Thanks...its just finding the time now to sort it, i want it for the summer, bodywork might not be the greatest this year, but as long as that engine is running then that can wait.

Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: dom on 27 March 2016, 11:43
Just flicked through all this, fair play to you for tackling it by yourself. When are you going to tackle it again?
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 27 March 2016, 20:00
I've got time off work on 18th April for 1 1/2 weeks, so hopefully it'll be done then, itching to get started lol

Thanks for looking, it's nice to see someone else appreciates the work put in,  :cool:
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 27 March 2016, 20:06
Ive been waiting for updates since i read this thread.
Theres a vr cabrio around here thats smart as anything
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 27 March 2016, 20:29
Oh wow!!  :shocked:  I didn't realise people were interested, that's nice to know, I will be updating it i promise,
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 27 March 2016, 22:06
Just because we dont comment doesnt mean were not reading and interested bud
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 28 March 2016, 12:42
 :smiley: that's good to know
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: unknown on 03 April 2016, 17:41
...bump as its one that inspiring me as well so waiting for updates.
Ive just replaced all the interior in my Mk3 Cabrio with Leather - trying to decide if I replace the mk3 4 spoke steering wheel with the mk3.5 3 spoke leather one - yes I know its supposed to be simple!
Ive also swapped the roof cloth to vinyl so a) temp fix and b) enables mne to dismantle it properlyt to repair the dreaded failed seam.
Now just need to get the BBSs refurbed and then.... and then....
So at some point I will be thinking of the engine so really interested to see how yours goes. Must admit the thoughts of a fried loom worry me but.....research research and watch always applies  :smiley:


Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 03 April 2016, 23:30
The fried loom Was my fault, I misplaced a wire, an important one it seems lol.. I'm back on this 19-4-2016, got a few things to do while I'm off(always the way isn't it, you take time off to do one thing, and end up with lots) mot on my Audi and cambelt on my other Golf...it's all go go go.

Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 18 April 2016, 15:11
Started back on this on Saturday, removed the dash, and started labelling the loom up, just tonight in work, then I'm off until just after Bank Holiday.

Hopefully, by time i go back to work, the engine will be out, loom replaced, engine bay cleaned up and engine degreased...just hope the weather holds out.

Once the engine is out, it can be cleaned up in the garage. I'm looking forward to getting this started..and earning some beers :grin:

Many more updates soon no doubt.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 19 April 2016, 19:00
Engine almost out again, few rounded driveshaft bolts that needed wd40'd and left overnight, should be out tomorrow.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: jimmydub on 19 April 2016, 20:32
Engine almost out again, few rounded driveshaft bolts that needed wd40'd and left overnight, should be out tomorrow.

they're a right pig them bolts!

I'm also watching your thread mate!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 20 April 2016, 09:10
Pictures??

I think everyone hates driveshaft bolts.
If it comes to it chop the heads off and get molegrips to remove whats left. Had to do it once. Hopefully youll get them though
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 20 April 2016, 19:44
Progress made!!!

Driveshaft bolts were a pig!! But smashed a 12mm bolt on each of them and cracked them off gently!! That meant only engine mounts left holding it in, strapped it up, did a final check and out it came.

(http://i107.photobucket.com/albums/m318/hardmonkeys/Golf%20Cabrio/8DEF0EAE-99B5-4C27-9C09-CBC81CFFA9E8.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/Golf%20Cabrio/8DEF0EAE-99B5-4C27-9C09-CBC81CFFA9E8.jpg.html)

(http://i107.photobucket.com/albums/m318/hardmonkeys/Golf%20Cabrio/1D395F9A-BA90-4B23-AF89-5A3C3D7788F8.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/Golf%20Cabrio/1D395F9A-BA90-4B23-AF89-5A3C3D7788F8.jpg.html)

 :grin: :grin: 

Then it came to removing the loom, so had to sort through my favourite bit!! The fusebox! Didn't take as long as last year, it all came back to me which was handy, took about an hour all in all

I manage to have a quick ganders at the state of the old loom, put it this way! I was VERY lucky.

(http://i107.photobucket.com/albums/m318/hardmonkeys/Golf%20Cabrio/D2CB7E2D-09FE-4304-B368-920F00A68E16.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/Golf%20Cabrio/D2CB7E2D-09FE-4304-B368-920F00A68E16.jpg.html)

(http://i107.photobucket.com/albums/m318/hardmonkeys/Golf%20Cabrio/17DB154B-86E5-47B9-B0C9-4F3ED0ECB390.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/Golf%20Cabrio/17DB154B-86E5-47B9-B0C9-4F3ED0ECB390.jpg.html)

This went to the coil!


(http://i107.photobucket.com/albums/m318/hardmonkeys/Golf%20Cabrio/C590C1A9-2E28-4C67-BCD3-1BFBAC34674F.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/Golf%20Cabrio/C590C1A9-2E28-4C67-BCD3-1BFBAC34674F.jpg.html)

(http://i107.photobucket.com/albums/m318/hardmonkeys/Golf%20Cabrio/50DD67BA-EA7A-4A4D-BBA2-6F1D2F2871D8.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/Golf%20Cabrio/50DD67BA-EA7A-4A4D-BBA2-6F1D2F2871D8.jpg.html)

And this to the fusebox, not yet check the full loom damage, but will report back with findings

So all in all a very productive day!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 22 April 2016, 15:07
Weather not been great the last few days, yesterday I managed to get the loom in, and wired up to the fusebox, all straight forward, just time consuming to honest making sure it's all thought without snagging wires.

Today I attempted to clean the engine up, took the inlet off and this is what I was faced with

(http://i107.photobucket.com/albums/m318/hardmonkeys/9B6A1B28-9D03-4B1A-9B4B-A4A0BA5320E1.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/9B6A1B28-9D03-4B1A-9B4B-A4A0BA5320E1.jpg.html)


Using GUNK engine degreaser and a paintbrush toothbrush and a microfibres cloths, it started to get there

(http://i107.photobucket.com/albums/m318/hardmonkeys/20A5167E-B14E-4A6A-ABAB-13D4FA5024F0.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/20A5167E-B14E-4A6A-ABAB-13D4FA5024F0.jpg.html)

(http://i107.photobucket.com/albums/m318/hardmonkeys/89619DA1-CB73-4083-8E83-BE8EF0BF24EC.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/89619DA1-CB73-4083-8E83-BE8EF0BF24EC.jpg.html)

Didn't get a pic of the end as it started to piss down. But I will.

I have scraped the muck out from the nooks and crannies of the block, but unsure how to degrease and rinse without getting water in the important parts of the engine, so going to clean up best I can.

Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 22 April 2016, 16:57
Brake cleaner. And a air line. Plus a tiny tooth brush
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 22 April 2016, 21:40
Any ideas where to get an airline. I'm doing this on my driveway remember
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 23 April 2016, 11:28
Ahhh yehsorry.not everyone has a compressor.
Brake cleaner should lossen it off ao you can get a flat head screw driver to pull it off the hard buts then wire brush the rest
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 23 April 2016, 13:21
 :smiley: thanks mate.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 24 April 2016, 20:08
It's in!!

Final checks today before the driveshaft were connected up, I replaced all the bolts with new bolts from VW, and all went ok, until I went to torque them up, my torque wrench is knackered!! So I've nipped them up, along with the engine mounts. On the look out for a decent torque wrench now.

So, aside from the torque wrench situation, all was going well, until I went to start it.... It didn't!

It tries too, and will start with some persuasion with a little throttle, but is rough as!! And running Very rich, as soon as i let go of the throttle it cuts out immediately.. I'm going to try changing the leads and plugs tomorrow, see if that helps

Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 24 April 2016, 21:22
Makes sure the inlet manifolds not leaking air in.
Good work so far though. You keeoing the car that colour?
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 24 April 2016, 21:31
Thanks pal, not sure on the colour yet, it'll be staying this colour for now, who knows what will happen in the future lol
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 26 April 2016, 19:41
Engine still not starting, I have changed the crank position sensor and ignition coil, but still nothing.

Will scan in the morning again see what comes up
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 26 April 2016, 20:00
Is the crank sensor that came outalright?
Can you heae fuel pump prime.

Checked for a spark?
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 26 April 2016, 21:35
The wiring on the old crank sensor was brittle and frayed, the fuel pump does prime, not checked for spark as yet, but have the rest of the week free to do some investigation, battery was going flat so will give it a charge tonight and have another go tomorrow.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 01 May 2016, 20:31
Spent the week replacing different part/sensors trying to find out why it wasn't sparking, speaking with some of you people on here and finally (maybe) getting to the bottom of it,

Replaced:

Finally when I was at the end of my tether, I pulled the ECU to rule it out I spotted this..

(http://i107.photobucket.com/albums/m318/hardmonkeys/DB284A1E-FFD0-4232-AC70-68C4ABDDFA4B.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/DB284A1E-FFD0-4232-AC70-68C4ABDDFA4B.jpg.html)

So, this is where it lies, I think...I reckon the old loom melting has caused this...so on the look out for a new ECU, or a decent repair
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 08 May 2016, 15:40
Found a ecu on eBay for starting price £10, figured I'll get it, see how it goes, and if it's a duffer, it's only cheap, anyway I bidder up to £20, ended up winning it for £13.50 and £6 postage. BARGAIN!!

Just hoped it worked, researched programming the Immob to it when it arrive and hopefully it works.

Few days later, think it was Friday it came through..I fitted it and programmed it...fingers crossed!!

IT WORKED!!!! it runs like a dream! So I began slowly putting it all back together..bled the coolant, and power steering and bled the clutch, and took it up and down the road To get it up to temperature, I had a slight leak on the coolant, so replaced the hose and jubilee clip, now it seems all good.

I have no indicators on the left hand side, hazards work just not the indicators, will have a look into that later, I'm in work later tonight, so having a rest from it all now.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 08 May 2016, 15:54
Fuse or stalks. Glad its nearly back together
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 16 May 2016, 13:12
Sorted the indicators, I nicked a wire put the dash back in, soldered back together, and all back to normal  :smiley:

Few trim panels to put back on, and bumper back on, the 'should' be ready for MOT. It needs a new screen, but struggling at the min, as I'd dropped the car to fire and theft while it was off the road...thus removing my glass cover!!! Adrian Flux won't let you upgrade the policy again until renewal...just in case people upgrade then a few days/weeks later all of a sudden have a cracked screen...So it's priced at £210... Trying to get cheaper
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 16 May 2016, 19:33
Thats an expensive screen. Surely you can get one cheaper though bud
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: madmanmart on 16 May 2016, 20:00
I've had one done at £100 fitted.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 17 May 2016, 05:29
Managed to get one. £90 fitted. Coming on Friday afternoon.  :drool:
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 08 June 2016, 12:53
MOT on Friday...fingers crossed!!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 08 June 2016, 15:00
Good luck buddy
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 10 June 2016, 12:31
Test abandoned lol  :grin: :shocked:

Bloody thing overheated during the emissions test, cooling fans didn't kick in and it let go of its fluids!!

Booked in for next week now. He said before he abandoned the test the emissions were sky high. Something else to work on now.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 10 June 2016, 19:20
Good old golfs ey?
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 10 June 2016, 21:13
Oh yeh!! Lol

I'm hoping the emissions are down to it sitting for 9mths and the engine being out, gave it a blast today on way there and back, and will do the same when it goes back in next week...it's pretty much had a new ignition components..fingers crossed
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 15 June 2016, 10:16
Did a vagcom scan on the Cabrio today, and it's coming up with Lambda sensor - no signal intermittent. So ordered a new sensor for tomorrow. Mot again on Friday.  :evil:

Also ran the car up to temperature and the fans kicked in as they should, so hopefully no embarrassing 'Abandon Test' scenario again lol
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 17 June 2016, 19:10
Took it for its MOT...:-

It failed...but not miserably..

Centre stop lamp not working (1.2.1b) :- corroded connection

Nearside headlamp aim too low (1.8)

Offside headlamp aim too low (1.8)

Power steering pipe(s) or hose(s) leaking from a joint (2.3.3b) :- new washer needed

Nearside front brake hose bulging under pressure (3.6.b.3) :- new flexi needed

Nearside electrical wiring insecure abs wire (1.9.2a) :- not sure, but I've cable tied away neatly
Power steering pipe(s) or hose(s) fouling other parts of the vehicle on steering rack n/s (2.3.2) :- this is the pipe I replaced offer the donor, just needs moving away.

Sub-frame attachment bracket/mounting bolt missing (2.4.g.1) :- Schoolboy error

Sub-frame attachment bracket/mounting cracked (2.4.g.1) this isn't cracked, it's a loose bolt..should need torquing up.

So all in all a 'successful' failure...so to speak..
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 17 June 2016, 20:14
Better than some.failures ive seen. All pretty simple stuff aswel.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 17 June 2016, 22:17
Very true. Silly little things. Won't make the retest tho as I'm away for a while. Annoying but not the end of the world
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 05 July 2016, 15:34
Back off my holidays now, new stop light received, and hopefully this week/weekend I can get the little bits done...then back in for test!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 09 July 2016, 20:22
In for test Wednesday 1pm fingers crossed
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: jimmydub on 10 July 2016, 23:47
best of luck! I've had a right 'mare with mine this time around
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 14 July 2016, 14:33
MOT PASS!!!

It needed the bulging brake pipe replacing, so I got them to do it, I now have a pass, just in time for some rumoured heatwave.  :laugh: :laugh: :laugh:
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 14 July 2016, 14:35
Roof down. 16v roar.
Well done mate
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 14 July 2016, 17:03
You know it mate!!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: madmanmart on 15 July 2016, 18:01
Good news
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 15 July 2016, 20:24
Thanks to you mate, you were a wealth of knowledge and I wouldn't of had a clue without it. Next time I'm up your way, I haven't forgotten I owe you some lots of beer!!!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: farrantino on 15 July 2016, 20:51
Amazing project, have enjoyed reading this. Will also keep an eye on this.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 16 July 2016, 11:11
Thanks. I've enjoyed it, and also detested it lol. This is far from finished, there is still lots to do, mechanically and some bodywork.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: th3_f15t on 17 July 2016, 09:59
Just caught up on this project as I've not had a chance to sit down and read it of late. Good, inspirational work there mate, glad to see it's not road worthy! You should be proud. Also, pictures please!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 17 July 2016, 10:55
Just caught up on this project as I've not had a chance to sit down and read it of late. Good, inspirational work there mate, glad to see its not road worthy! You should be proud. Also, pictures please!

Lol...cheers mate...I think..

Will get some pics soon, I hate photobucket...it's seems such a faff to get pictures up...I'm using an iPad too, so it takes bloody ages

Thanks for reading, it's nice to know that people are interested and I like to thing I'm helping others become inspired to take on something like this.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 17 July 2016, 12:47
Imgur.com thats what I use. New photobucket is wank.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 18 July 2016, 00:14
Excellent. Thank mate. Will give that a go
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion.
Post by: hardmonkeys on 22 July 2016, 13:46
hey hey

I had a small problem with the speedometer not working and fuel gauge not reading correctly, enquired on here and had a quick scout around the internet, and found it to be the Vehicle Speed Sensor in the gearbox,

(http://i.imgur.com/R1SglPc.jpg)

I removed the sensor and tested it by connecting it to the chuck of the drill, set my phone up to record the clocks in the car, fired the drill up, NOTHING!!

experience should of told me to stop there, get a new sensor and be done with it...but no no NOO!!

I decided, once I was there, I might as well changed the pinion too, seeing as it been there 19yrs!! surely new is better...right?? wrong!!!!!!!

so I take out the pinion and pinion guide, separate them, to see whats what

(http://i.imgur.com/0RtFek2.jpg)

clean it up, decide that it is actually ok, put it back in the guide, place into the gearbox and!!

..drop..... out the guide into the box..!!

i spent the best part of 2 hrs trying to fish it out, replaced it with the new pinion and finally sorted it...

nightmare few days, but at least the speedometer is now working, and the fuel gauge is reading correctly.

isn't it amazing how one sensor can affect so many different things

Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 22 July 2016, 13:59
quick picture from this morning in the yard before i came home from work

(http://i.imgur.com/x1bSaoB.jpg)
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 31 July 2016, 14:22
Took the Cabrio for tracking in Wednesday, into County Tyres in Weymouth, used these guys a,to over the last few years, so know they are genuine.

Anyway, they got it up in the air, and began to set up the tools, he looked a bit confused, so he got the manager over to look at it, came over to me and asked if the car had been in an accident....

I thought I'd made a cock up with something, so I told him what I had done with changing the engine,gearbox, suspension etc etc...he told me the wishbone on the N/S/F was an inch shorter than the O/S/F..which was the correct length....good old euro car parts!! I had noticed the wheel looked different, but thought it was because the tracking was miles out..

Can't take the wishbone back as its been on a year, so looking to get a new one, trying to avoid ECP now...any ideas on where to buy?




Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 31 July 2016, 14:31
Gsf or if you were a little closer id say apd. Gave you a non gti wishbone then
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 31 July 2016, 15:00
Not sure, The original wishbones had a different balljoints.

Looked online, vw parts international have genuine ones for £48...
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 31 July 2016, 15:02
Thats not a bad price to be honest
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 31 July 2016, 15:04
That's what I thought..least I know it'll be of a decent quality...id hope so anyway
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 18 August 2016, 16:27
Not forgotten this, just enjoying the roof down action  :laugh:
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 12 September 2016, 22:55
Took the Cabrio for tracking in Wednesday, into County Tyres in Weymouth, used these guys a,to over the last few years, so know they are genuine.

Anyway, they got it up in the air, and began to set up the tools, he looked a bit confused, so he got the manager over to look at it, came over to me and asked if the car had been in an accident....

I thought I'd made a cock up with something, so I told him what I had done with changing the engine,gearbox, suspension etc etc...he told me the wishbone on the N/S/F was an inch shorter than the O/S/F..which was the correct length....good old euro car parts!! I had noticed the wheel looked different, but thought it was because the tracking was miles out..

Can't take the wishbone back as its been on a year, so looking to get a new one, trying to avoid ECP now...any ideas on where to buy?

Hi all, just an update on the Cabrio, haven't driven it much over the last few weeks, as I've been waiting to get the wishbone sorted, finally cracked on this weekend,

Took the troublesome wishbone off, after I bought another one from ECP, a different brand this time, took the old one off, measured them up to see the difference, nothing...no difference! Now I'm annoyed and confused...and frustrated as I now have no idea where the adjustment is coming from, I checked with VW as thought they'd surely will have the correct part, they advised me that it's been superseded with..Jacksh!t, the nice bloke up there gave me a number for VW Heritage in Shoreham, W Sussex, but they can't get hold of them either..but in his experience, the only wishbones for the GTi he has come across is the 8v ones, (which I had on it in the first place) and the ones for the 16v and the VR6, which is the one I've got...

I put into ECP the model and engine of a VR6 to see what came up, and it was the same wishbone I had in the first place, grrrr!!!

So I put the original wishbone back on, and took it back to County Tyres...and explained, that's the only wishbone there is for a GTi 16v, he put it back on the ramp...and managed to track it up!

I think he was looking at the car as a normal model...not a GTi, which it is in all but model...despite me telling him it had Been converted...

Waste of a weekend!!!


But least now it's tracked, it doesn't feel great if I'm honest, so I will have another look underneath again over this weekend, just to be sure

Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 25 September 2016, 16:14
Had another look at the wishbone problem this weekend, asked about the forums, turns out the camber was out from when I changed the hubs, didn't realise they have so much adjustment. Anyway, using a spirit level I crudely corrected it and now it feels a lot better.

I'm looking to buy a camber adjustment tool from machine mart, as recommended by gasketface on here

https://www.machinemart.co.uk/p/040817066/?da=1&TC=GS-040817066&gclid=CPC2q9mIqs8CFWgo0wodpHEF7Q

So I can do it properly. I'm gonna need bigger toolbox at this rate!
Title: Time to go away for the winter
Post by: hardmonkeys on 23 October 2016, 16:50
(http://i.imgur.com/Q2slZvM.jpg)

(http://i.imgur.com/2OoWyoI.jpg)


The time has come to put the car away for the Winter!  :angry: its in a better position than when i put it away last year, as it was about 12-13mths ago the wiring loom burnt out.

Lots of jobs to do over the winter, some might get done...some might have to wait  :undecided:

Thats the beauty of a on-going working project

Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: th3_f15t on 10 January 2017, 19:41
Look forward to when the updates begin again mate, will be good to see in the summer.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 11 January 2017, 06:31
I've not been able to help myself, I've been using it over the weekends for the last couple of weeks...lol

It struggles to start at the moment, well,  it so much start,  it starts fine, just a little lumpy while it warms up, but aside from that, it's great, still got to do the little jobs before it gets to spring/summer, hopefully they'll be done
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 11 January 2017, 19:34
Good to hear. If use it all the time. Problem i have when the mk2 is insured i cant help but drive it and the passat or a4 just sits there
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: th3_f15t on 12 January 2017, 13:33
I've not been able to help myself, I've been using it over the weekends for the last couple of weeks...lol

It struggles to start at the moment, well,  it so much start,  it starts fine, just a little lumpy while it warms up, but aside from that, it's great, still got to do the little jobs before it gets to spring/summer, hopefully they'll be done

I'm sure there's a guide or two out there to cure lumpy idle when cold, but it's a low priority at the moment I guess. Damn right you should use it, you built it...
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 12 January 2017, 15:36
Thanks. I had a drivers CPC course to do last week in Poole, (I'm in Weymouth) so I took it, expecting a few niggles, it was the furthest I'd took it since last summer, and it ran like a dream, after it'd warmed up lol, I even managed to get the roof down :-))

Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 27 January 2017, 02:22
2yrs ownership today :-)
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 30 January 2017, 23:26
Hello, I'm looking to get the rear brakes done on the cabriolet, but im under the understanding that you need to replace the bearings too, now I'm fully aware this can be a little difficult, as too loose and the wheel can fall off, and too tight and it could, worse case, set on fire...don't really want either lol

I called a local mobile technician I've used before and explained it all to him, and he didn't seem to happy to take the job on, as it's not standard going back on, which annoyed me as he was egging me to get the project underway, and praised my work lol...

So....I've decided to try to do it myself, so...any advice lol...I have all the parts I just need the advice

Thanks
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 31 January 2017, 08:53
Bearings easy. You want to do the nut up so it bights with a ratchet and turn it back quarter turn. (Thats what i was tought at college and its never failed me)
Then spin the wheel to see if it moves freely.
It should definately. Then just rock it like you wpuld to check for play.
Youll sort of know if its to tight because it wont spin as free and also when you take it for a drive and check afterwards itll be really tight to turn.
And youll know if ots to loose by checking for play.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 31 January 2017, 13:54
Do they need pressing in?
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 31 January 2017, 13:56
The bearing races need knocking in ant out. Ive never pressed a set in.
Use a socket or screw driver to get the old races out. The a suitible sized socket and some grease to put it back in.
Tap it gently. Doesnt take alot.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 31 January 2017, 14:33
I've got new discs, so that'll save knocking them out won't it. You made it sound easy so when the weather is better I'll have a go.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 31 January 2017, 14:53
I think its easy.
Ive done it enough times to be fair.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 03 February 2017, 16:22
excellent, thanks. Weather is crap!! just want to get out get some niggly jobs done
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 03 February 2017, 19:05
Weekend is suppose to be nice. Im hoping so anyway so i can do the mk2
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 04 February 2017, 15:16
weekend so far so good....apart from the seized O/S/R brake caliper piston  :cry: :cry: :undecided:
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 04 February 2017, 15:18
oh and the battery is flat...again!! only drove it on Wednesday..something is draining the battery while ignition isn't on

 :angry:
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 04 February 2017, 15:48
Are you sure the battery isnt just knackered?
Check the earth on engine and check the live to the starter for loosness
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 04 February 2017, 16:02
It was a new battery last year, will check the connections, gonna try get the piston sorted first..
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 04 February 2017, 17:32
Done OSR  :smiley: :smiley:

Now for the NSR, Piston is moving, but not winding back, marvellous!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 04 February 2017, 20:08
Got it moving, and pads are in..then it rains lol Great!!

Anyways, the pads really did need doing!

(http://i107.photobucket.com/albums/m318/hardmonkeys/IMG_0034.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/IMG_0034.jpg.html)
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 05 February 2017, 08:05
Loads of life left in that.  :grin:
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 05 February 2017, 13:33
You can use the metal too can't you, makes a little bit more noise, with added sparks for dramatic, pyrotechnical purposes :laugh:
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 05 February 2017, 17:37
Its all the rage using the metal. I hear once this disc is gone its time to change the lot. Not before though or you dont get you moneys worthe  :grin: :grin:
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 08 February 2017, 14:15
Spend a couple of hours sorting the discs and bearings out,

(http://i107.photobucket.com/albums/m318/hardmonkeys/IMG_0418.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/IMG_0418.jpg.html)
 

Didn't take as long as I thought, 1hr 1/2, and that was getting a new abs ring too, as one broke, £21.99 from Ecp

(http://i107.photobucket.com/albums/m318/hardmonkeys/IMG_0419.jpg) (http://s107.photobucket.com/user/hardmonkeys/media/IMG_0419.jpg.html)

Finally on matching wheels for the first time since April 2015 lol

Not a massive fan of them,  but they'll do for now...I think we can say...Conversion complete, although that's not the end of this project, plenty more to do, now it's making it look decent...told you, you wouldn't get rid of me that easily lol

Feeling good about this summer!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 08 February 2017, 23:33
Spray it pink. And stick some proper sick jdm wheels on it. Against the grain...


Look pretty decent mate, i was looking at these the other day to bank a 20vt into that ive got sitting about
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 08 February 2017, 23:48
That would be amazing! If you do it, you must blog it, I'd love to keep up to date with that! I'm looking into getting her roof repaired now...

Will be trying to sort the drivers window out tomorrow, it doesn't go down all the way, and has a slight gap in the corner
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 08 February 2017, 23:50
Might do... Finish some other things 1st.
Its finiding something i want to build.

New cover for the roof is it
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 09 February 2017, 15:20
Possibly, doubt it can be repaired,  but they can perform miracles nowadays can't they
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 11 February 2017, 19:57
I must be mad, I've taken on another project...lol Audi A2, apparently has a blown head gasket...not sure as yet

Cost?? £0  :laugh: yes!! ZERO! FREE!! NADA!!!

Ive started a new thread here

http://www.golfgtiforum.co.uk/index.php?topic=279777.msg2558191#msg2558191
Title: Battery Flat again!!!
Post by: hardmonkeys on 14 February 2017, 06:01
Not sure what's causing the battery to flatten so quick, drove it Thursday to give it a run, it was flat by Sunday morning...I've disconnected the amp I fitted before I put it away,just in case than was live permanently, might remove the radio, see if that helps, hate electrics, it's all trail and error  :grin:
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: Alanw. on 14 February 2017, 22:05
Almost looks the same as mine mate , keep up the good work ...just fitting a 20vt into mine at the moment
(http://i1255.photobucket.com/albums/hh639/TrooperErin123/IMG_3328_zpsarpnnisl.jpg) (http://s1255.photobucket.com/user/TrooperErin123/media/IMG_3328_zpsarpnnisl.jpg.html)

(http://i1255.photobucket.com/albums/hh639/TrooperErin123/IMG_3515_zps5dgjz0mc.jpg) (http://s1255.photobucket.com/user/TrooperErin123/media/IMG_3515_zps5dgjz0mc.jpg.html)
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 15 February 2017, 02:38
Wow!! Excellent picture! That's given me some inspiration

Thank you, yours looks very nice!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: Alanw. on 15 February 2017, 09:13
I love the little golf but for me it was so sluggish with the 2.0 8v . Great car to drive , sitting on coilovers and borbet A's . Colour will be changing though , going the same as what I've painted the engine bay .
(http://i1255.photobucket.com/albums/hh639/TrooperErin123/IMG_2627_zps9dmquuxz.jpg) (http://s1255.photobucket.com/user/TrooperErin123/media/IMG_2627_zps9dmquuxz.jpg.html)
Title: Great looking Car
Post by: hardmonkeys on 16 February 2017, 15:32
mine needs alot to get it to the standard of yours..Its nice to see someone still loves the mk3.5. They are a great car, and i'd say quite easy to work on

Title: Battery draining issues
Post by: hardmonkeys on 16 February 2017, 15:44
Hopefully this weekend i'll be finding out whats draining the battery so rapidly....I moved it last night, so had to quickly jump it off my mk5, parked it up, and left it, just been out to it now, and the battery is flat....i mean FLAT!! very faint dash lights, central locking not even working.

Looking to test the alternator tomorrow, then stripping things down and disconnecting them one by one...could be long winded process...any clues on how to find whats draining it so quickly?

Its obvious its something I've done during the loom swap last year, as its never done this before.

I disconnected the amp I fitted last year, from the battery, so its not that, the radio hasn't face on it, I wonder if it could be the ignition switch i replaced last year, when i take the key out though, there are no lights on the dash?

I could end up stripping this down again for the 3rd year in a row lol, Obviously it could take a few days aswell, as i'll charge the battery up, and its normally a few days of sitting before it drains on a fully charged battery, I'll have to set up a multimeter to check for significant drop in Voltage

*sigh* still a few more weeks to sort it before the 'Roof down' season starts, and I've got to remember, its in a better condition than this time last year..

Title: Battery drain findings
Post by: hardmonkeys on 18 February 2017, 14:48
Just connected a multi-meter up, while running, it's showing 13.96v, when all auxiliaries are on, fluctuates at between 12.5-12.8v. When engine off its at 12.2 but drops 0.01 every 2 seconds or so, so not a dramatic decrease, but something is draining it....
Title: Battery
Post by: hardmonkeys on 18 February 2017, 18:34
didn't get very far with this today...i ended up taking it for a drive :laugh: :laugh: :laugh:

sun was out, weather was dry....ROOF DOWN TIME!!

i have checked the voltage and it was 12v, so will check in the morning see how much its dropped by
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 18 February 2017, 20:40
And thats why i would have a cabby. Roof down moments
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 18 February 2017, 21:13
Agree  :laugh: :laugh: :laugh:
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 02 March 2017, 18:19
washed the cabrio today, scrubbed the roof to get the mildew off. will get some pictures tomorrow when it drys
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 22 March 2017, 05:20
having a few problems with starting the Cabrio, it starts, but is so lumpy, sounds rough as anything, smells of fuel and is kicking out a bit of smoke too, will check the norm later, leads plugs etc, but as soon as its warm-ish, it runs fine..until i switch it off, then it struggles again, could be like 5 mins, like filling up with petrol, its almost as if its flooding while the engine is off, because as soon as the engine starts, smokes a bit, its fine, as if its burnt off excess fuel,

strange one
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 22 March 2017, 11:38
Check the earths.
Cant think does a abf have a cold start valve or is it done by ecu
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 22 March 2017, 14:15
I must admit I was thinking ECU, as I changed it last year as the original one got fried when the loom did.

Just started it now, and it a lumpy for about 30-45 seconds, really chugging, now absolutely fine lol. Almost like I'd forgot to pull the choke (remember them lol)  out.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 22 March 2017, 19:39
Ahh is isv working or one of the temp sensors on side of the head not workin.
Running through these problems on my mk2 at the moment.
I dont have a tickover though.
Wish i had a choke for such occasions
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 19 April 2017, 06:10
Quick update,

Wish I could say I've been enjoying the roof down action...I haven't, the car has sat at the end of the road for a few weeks, not broken, I've just had a few other things to sort, I'm starting my own business so have been manic busy with sorting that, I injured my ankle on Easter Sunday, so spent most of the day up A&E  :undecided:

Car still rough on start up, going to give it a full service when I'm back on my feet, got to be worth it, going to replace the leads for better quality ones.

That's where we are at the min....its in a lot better state than 1 yr ago!!

Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: lemski on 19 April 2017, 09:43
Good luck with the business venture.
On this cold start problem have you checked the gasket between tb and inlet. See if its sucking air when cold but seals when the inlet gets warmed.
Just a thought
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 19 April 2017, 11:44
I had thought of that, will have a look some, think I also have a spare gasket some where too

Thanks
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: mvb on 29 June 2017, 13:13
what an excellent read, well documented and inspirational.

i have a problem with my clocks at the minute and wondering, when your clocks where playing up, did the mileage count work?

my speedometer and tachometer are in a world of there own.

thinking i might start a build thread, but mine will take a long time as got so many other things to sort out and the cabrio is bottom of the pile.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 30 June 2017, 19:07
thank you!

no, when the clocks were playing up, the mile counter didnt work either.

I will get back on this soon, MOT is up again in July, (i know!!) but its been laid up for a few months due to a oil leak, and lack of power...and now ive started my own business with ChipsAway, so i am concentrating on that for the time being, will try and get some things sorted on it for the start of the summer next year now....seems ages away, but it'll soon come round...again

Oh and we are having another baby!! yep!! a mad crazy year ahead
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 01 January 2018, 18:03
Hey hey,

Car still on the back burner for now, baby very imminent...any day now,

Pulled it out of the garage to have a clear up in there..battery very duff (as expected seeing as I’ve not done anything with it lol) runs rough until warm. Left it running while clearing up, massive oil leak looks likely, maybe a sump gasket...so adding that the list of things to do 👍🏻👍🏻

Had thought about selling her, due to it not being used as often...but figured it’s not much to anyone really, and when I got in it today....I realised...no way am I selling, I just love it
I’ll try keep this updated as when I can.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 07 September 2019, 18:21
....still laid up, baby is now 21mths old, car still in the garage, being used a shelf  :cry:

one day....it will be on the road, would love it to be next year, as it'll be 20yrs old...but looking unlikely.
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 27 March 2020, 11:04
Good Morning...

how are we all during this pandemic situation, my business has been closed temporary until further notice, so figured I'd have a look at the old b!tch, haha

so...new battery purchased, started first time, but sluggish as...f@ at start up, as before, but now the battery light is on constantly... :sad: add to list of things that need doing, would love to get it up and running this year, can't see it to be honest,
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 25 February 2021, 19:14
Hello all,

I'm trying to find time for the Cabrio this year, went out today to attempt to start her up after last years failed attempts!! to my surprise she started up first time :laugh: :laugh: :laugh: :laugh:

a little sluggish at first, but once warm ran lovely.

we have a few issues though, hopefully minor stuff, but Battery light is on, brakes seized, tyres flat...standard 'laid-up' issues, she's coming up for 21 yrs old this year, so I would like to be using her during some Roof down summer nights...long way to go!! but fingers crossed!! will keep you all updated!
(https://i.postimg.cc/9XDtd6cQ/090-CF937-55-E6-4140-84-B1-6-CDBC5-BD0798.jpg) (https://postimg.cc/qgd30ZtP)
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 27 February 2021, 18:07
New Alternator and drive belt fitted today!
(https://i.postimg.cc/9f2qjBm7/6561-F696-9-B2-C-4-C32-AE67-48-E2-BAC75531.jpg) (https://postimg.cc/xXsdvMbf)

Tried to order a new PAS belt seeing as it was coming off anyway, but couldn’t get one for today! It’s in good Nick anyway, so will add to the winter ‘maintenance’ list if get on the road or the ‘to-do’ list if it doesn’t...I think the brake seize is the handbrake mech on the OSR caliper and seems like it is freeing itself after being doused in WD40 yesterday...I’m 1/2 tempted to book an MOT on it, to see what is what.....new tyres first they are perished and cracking! 4 yrs of sitting around apparently does that 🤣
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 01 January 2022, 20:44
Soooo, New Year new dreams!!!

I didn't get the car out this year as I was ill, so I took some time off work, 80% better now, so here goes!!

This year WILL BE the year it gets on the road...its about 5 yrs since it was last used...I will be taking out the garage tomorrow to make a list of things to do...and hopefully get it booked in for an MOT within a month or so.

Wish me luck all
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 11 April 2022, 20:07
SO...for the first time in 5yrs...!!! SHE HAS BEEN DRIVEN!

I took her from my house to workshop, where I'll be sorting things out, and getting into for a MOT..

exciting times again
(https://i.postimg.cc/CMrkSpjy/278267041-10158342143492397-5226087368822273272-n.jpg) (https://postimages.org/)
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 15 March 2023, 17:41
New Loom and engine bought!!

I am removing the engine for the 3rd time, and replacing the troublesome loom!! hopefully this year it will be back!
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 05 October 2023, 15:57
 :laugh: :laugh: :laugh: MOT booked!!!!!! First one in 8yrs! Here’s hoping it’s not too bad
Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 14 October 2023, 21:51
 FAILED!!! lol

Do not drive until repaired (dangerous defects):
Nearside Front Brake disc in such a condition that it is seriously weakened INNER SURFACE (1.1.14 (a) (ii))
Offside Front Brake hose ferrule excessively corroded and likely to fail (1.1.12 (f) (ii))

Repair immediately (major defects):
Nearside Rear Wheel bearing has excessive play (5.1.3 (a) (i))

Monitor and repair if necessary (advisories):
Offside Front Brake disc worn, pitted or scored, but not seriously weakened (1.1.14 (a) (ii))
Nearside Rear Brake disc worn, pitted or scored, but not seriously weakened (1.1.14 (a) (ii))
Offside Rear Brake disc worn, pitted or scored, but not seriously weakened (1.1.14 (a) (ii))
Nearside Rear Brake hose slightly deteriorated (1.1.12 (b) (ii))
Offside Rear Brake hose slightly deteriorated (1.1.12 (b) (ii))
Central Exhaust has a minor leak of exhaust gases JOINT (6.1.2 (a))

Not a bad fail sheet after a 6yr lay up I’d say!

Title: Re: hardmonkeys - mk3.5 Cabrio 2.0 8v auto to 2.0 16v manual conversion
Post by: hardmonkeys on 30 October 2023, 21:20
And we have 12mths MOT on the car!!

Woo hoo!!