Author Topic: mk2 scrapyard - 2.0 16v rebuild  (Read 10177 times)

Offline jv

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mk2 scrapyard - 2.0 16v rebuild
« on: 14 May 2006, 19:25 »
here you go :)
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Offline Devon Joe

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Devon Joe's Mk2 2.0 16v conversion
« Reply #1 on: 14 May 2006, 20:27 »
Ace, thanks jv!  :smiley:

Well a brief introduction to my motor:

MK2 1989 GTI 16v 3dr in Helios Blue. standard height, small bumpers & BBS RA's

I bought it for £400 a year ago to replace my dead 8v GTI, the dude i bought it off had stripped out its factory black leather ( :cry:), thrown in some 4dr seats (no recline!) and then chucked it in the freeads. I figured it was worth it as the BBS' are pretty valuable now anyway. Car is pretty dinged, and really needs a respray (spent most of its life in Bristol so rear quarters have been properly carparked)

Ragged it about for a while, found some 3dr front seats (ones a rainbow the other is that square print..) and took off the chav DTM exhaust, flogged it and then bought a new OEM system which was quieter and cooler. Bought some new small bumpers and a few trim bits and fitted my tow bar for boats and stuff.

After a few months it blew a core plug on the head, fixed that, head gasket went, fixed that and did the stem seals/reground valves too.

Then i picked up an Audi 80 Quattro from Feebay for a whopping £67.00, drove it home and then stripped out the 2.0 6a engine...which is where this project began   :grin:


Took out 1.8 KR and swapped all bits over to stripped 6a lump- it had a "recent head rebuild" so i didnt bother swapping heads and just swapped the KR cams over. Fitted the lump to a spare 8v gearbox (longer 5th) and fired it up. Engine ran nicely but i'd stupidly put in the 16v friction plate which has different splines to the 8v box and a "grrrrggraaatttttcchhrrrrshhh" sound meant the whole lot had to come back out and a new 8v clutch went in  :rolleyes:

Gearbox was lovely in my 8v, quiet, easy selecting all gears etc but the torque form the 2.0 lump turned gearbox into a whinging mass of rumbly steel in about 5months. I expected the smaller 8v clutch, which was a cheapo crappo LUK to die first!

Took the GTI to Cumbria from Devon for a mates stag weekend- 650 mile round trip with 3 fat blokes and luggage and pretty much killed the car. Front wishbone bush failed on way up and the wheel could be moved about 10mm front to rear (!) which ripped all the tread off my nice Firestone Firehawk, boot lock came off in my mate's hand and the speedo broke...I reckon it was Carma- the clutch also started slipping so i think the crankshaft end seal has gone.

So....plan this month is to take engine out of car again, strip it and check it over, put my old head back on and work out how to fit a Passat gearbox. Also have been offered a set of Kehin carbs off an R1 Yamaha motorbicycle for £80 which i may be tempted to try and fit too  :laugh: Have picked up a set of wishbone bushes which i will fit once the engine is out.

Will try to take pics, easier now the evenings are longer :smiley:
If only my Volkswagen was as reliable as everyone else's...

Offline Devon Joe

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Re: mk2 scrapyard - 2.0 16v rebuild
« Reply #2 on: 17 May 2006, 21:08 »
For a laugh i bought an Escort van (1.8 diesel..mmmm) for £100 with tax and mot thinking i could rag it around and use it for work and then flog it once the valver returns. Good in theory..
Have just had to pay £90 for a sodding engine mount!!! And plus it now needs tax and insurance. Well there goes my stainless manifold  :embarassed:

Have now decided to do gearbox, wishbone mounts and clutch asap so i can hopefully run it down to rtts. Fingers crossed the crank end seal isnt gone but as i am goikng to have to pull the clutch assembly of to see it, i may as well fit one anyway!
If only my Volkswagen was as reliable as everyone else's...

Offline Devon Joe

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Re: mk2 scrapyard - 2.0 16v rebuild
« Reply #3 on: 17 May 2006, 21:09 »
whoa i meant the mk2 is going to rtts- the Escart is only gonna be driven at night in case anyone sees me..
If only my Volkswagen was as reliable as everyone else's...

Offline Devon Joe

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Re: mk2 scrapyard - 2.0 16v rebuild
« Reply #4 on: 24 May 2006, 23:49 »
arses, if only this rain would stop i might get something done...
If only my Volkswagen was as reliable as everyone else's...

Offline Devon Joe

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Re: mk2 scrapyard - 2.0 16v rebuild
« Reply #5 on: 25 May 2006, 23:49 »
Picked up a new speedo cable today from GSF...twenty seven quid!
 :cry:
If only my Volkswagen was as reliable as everyone else's...

Offline Devon Joe

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Re: mk2 scrapyard - 2.0 16v rebuild
« Reply #6 on: 31 May 2006, 00:15 »
Missed RTTS as i had to go to a wedding anniversry (yawn) but managed to get some mk2 time in over the weekend. Did the front wishbone bushes on both sides, which was sooo much easier than i thought! Ze process:

1. Jack car up and remove wheelios
2. Unbolt anti roll bar bush
3. Rmove 3 13mm bolts under the hub and it pulls straight off the wishbone  :laugh:
4. Unbolt front and rear wishbone bolts and prise wishbone free.
5. 'Carefully' remove old rubber and hacksaw through steel sleeve to remove rear mounts.
6. Drill series of small holes around front bush to allow it to be knocked out on each 'bone.
7. Refit new mounts with some WD40 and a large bench vise.

And i broke no tools or any other entirely unconnected parts... :smiley:
If only my Volkswagen was as reliable as everyone else's...

Offline Devon Joe

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Re: mk2 scrapyard - 2.0 16v rebuild
« Reply #7 on: 02 June 2006, 00:40 »
Sun came out today and so did the spanners.
This evening i decided to have a go at the slipping clutch..

1. Unbolt everything connected to gearbox ie bolts/wiring/linkages/wires that go nowhere at all
2. Remove solid front engine mount completely.
3. Remove rear (gearbox) mount bolt and then remove the bracket from the gearbox with air powered Son-Of-Satan Torque-o-matic Wizz-Bang on rusty old bolts.
4. Lie under car and randomly twist heavy gearbox to release driveshaft cup from pointless steel lugs on block. One sore shoulder, face full of gearbox oil and seven brand new swear words later..
5. Remove clutch friction plate (oily) and clutch pressure plate (very oily) from engine block, exposing crankshaft end seal (effing oily...theres a theme).
6. Punch air with joy at having taken apart the correct broken bit of mk2.
7. Find out to surprise that GSF Exeter have all parts required:

1xCrankshaft end seal
1xSump Gasket
1xtrack Rod End (also buggerd)
1xcam chain (i think/hope its knackered and will get rid of odd camshaft grumble)

Also pleased to find that speedo cable has sheared- thank fork! Used Gieser(?) degreaser and a spatula to clean oil from various clutch bits so hopefully its gonna be fine. Cheapo LUK friction plate shows a fair bit of wear already...teach me for being a skinflint! Car still has tax till august so i think passat gearbox can wait.

I did take some pics but frgot to take kamera back homevwith me-if i work out how to upload i will :smiley: 
If only my Volkswagen was as reliable as everyone else's...

Offline Devon Joe

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Re: mk2 scrapyard - 2.0 16v rebuild
« Reply #8 on: 02 June 2006, 10:43 »
Stopped in at GSF on way to work and picked up a crank seal, complete tie rod (they didnt have the ball joint on its own..typical gsf service), new cam chain and a fresh rubber sump seal. Obviously gsf didnt have the crankshaft seal cover plate gasket either which was £1.65 from Mann Egg.

Now I like gsf as they offer all the parts i need for my ropey mk2 but jeez do they always seem to feck it up.  :angry: I phoned the dude during the week and was promised the ball joint was in stock. And why would they carry a crank seal but not the equally important gasket that you need for the plate that holds it against the damn engine?? ALS are much better guys but they always have to order stuff so i guess im stuck with gsf..

hoping to drive mk2 to london on sunday, hence the rush :smiley:
If only my Volkswagen was as reliable as everyone else's...

Offline Devon Joe

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Re: mk2 scrapyard - 2.0 16v rebuild
« Reply #9 on: 03 June 2006, 17:53 »
Did all the above last night and wahay! transfomed the front end so much i treated the GIT to a pair of spanking new Toyo Proxes..

Clutch still slips though- i now think its the pressure plate rather than oil so i am sorting out a new spare clutch kit at the mo.   :undecided:
If only my Volkswagen was as reliable as everyone else's...