GolfGTIforum.co.uk
Model specific boards => Golf mk2 => Golf mk2 gallery => Topic started by: jv on 13 March 2005, 17:33
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background:
Interior
Standard mk2 golf gti interior
Had a tiny Momo steering wheel on when i bought it which was awful without power steering! £15 later late 90 spec leather steering wheel fitted.
seats are buggered so will be rwmoving and putting mk4 3 door interior in going for the doorcards as well. :laugh: :laugh:
Exterior
Monza Blue factory colour limited run and my favourite VW colour. cheap 2!!
dings and dints here and there and a rusty bootlid.
lexarse lights on at the mo but not for long!
14" BBS? wheels to be changed soon!
Engine
KR engine code 1.8l Kjet 16v with
Ported polished gasflowed head
ported and polished inlet manifold
drilled airbox
4-1 stainless exhaust and full system
Autocavan air scoop
90 Amp alternator
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Hi guys and Gals
This is an ongoing post as it is an ongoing car!!
Lets start with what where and when and why! Bring you up to speed with things so far mainly fixing neglected problems
saw this on edition38 the quietest forum in the world but I thought immediatley I want that one! so emails were sent and I travelled 300 miles to pick it up. Got to the guys house and had a good look around the car decided definitley want that one had some bits here and there but not bad at all + a rebuilt engine 30000 miles ago.
Test drive went OK rubbed on drivers side but was low at that point so I thought it normal (mini used to do the same) as we were coming back the battery died after a good few hours a new alternator was found and fitted all working fine now. 300 miles home not a hiccup most chuffed.
got back and did the usual jack it up and inspect everything which was when I discovered the cause of the rubbing and lack of good handling, A snapped spring in 2 places really un amused. photo.
(http://img.photobucket.com/albums/v495/sharemaster/Picture7.jpg)
So went a hunting on Ebay and found a pair of front spax coilover dampers cheeep so bought those and got springs and a spanner from spax. Fitted those now handles like the go kart I was expecting.
Then came the oil and filter change, no real problems no metal chunks in the oil and not too dark ran engine flush through and pulled out loads of gunk filled with a decent duckhams mineral oil and oil is still as clean as it was when i changed it. Changed dissy cap and fitted a spitfire bought from dubfreeze, need to do plugs but don't like how far down they are so garage job.
talking of garages going in on 4/4/05 for clutch, timing belt new timing belt cover clutch cable gearbox oil change and general service.
Brakes were not as keen as I would like driven a cruise missile so gsf sent a pair of front brembo max discs and pagid fast road pads it now stops better than my 51reg Bora ding dang do!
so I can go and I can stop but it sounds like I have a G60 it whistles from the alternator/water pump so I had the alternator rebuilt and changed the water pump and pulley thermostat and housing for brand new GSF parts. New belts tried 4 now still bloody squealing so can of WD40 on belt no more squeal gets warm squeals WTF??
Bodywork is in good nick for an 18 year old car, Boot is shot to pieces rusted right through demist doesn't work so Ebay and a freshly seam welded smooth bonnet is on it's way. 1p sized rust bubble on front of rear arch and above the windscreen is starting to show a tiny bit of surface rust but otherwise sound as a pound!!!
anyway enough history I'll update as and when I change things on her.
Scott
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BTW took of the lovely clear lenses and fitted a nice new pair of hella oe smoked lenses looks loads better just for that also added debadged front grill new smoked fogs smoked side repeaters. got an original set of vw multispokes which are getting refurbed and black chromed anybody know where this can be done? yorkshire area. going to Elescar VW show on sunday so probably be posting Monday with more Bought bits!
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Well been to the garage at lunchtime to get my alignment and tracking looked at after a huge 4 wheel drift this morning which was fun in a way but I wasn't even caning it, now I have a bit more control on the corners but my steering wheel is wonky, gonna have to go back also ordered 2 new rear tyres for her and hopefully get some handling back won a pair of avo coilovers on Ebay so the handling will be improving hopefully, also going to the garage for Clutch and cable, Cam Belt and Tensioner, new cam belt cover and gaskets studs n stuff general service and find out why that bloody fanbelts squealing! and maybe get him to replace my top strut mountings with something a bit heftier maybe g60 maybe powerflex.
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She's been to the garage and needed a new clutch cable, clutch is fine :grin: and new timing belt, tensioner and cover, need a fanbelt cover from a mk3 to stop the squeal!!!. Changed the ignition barrell and fitted green leds to the instrument cluster looks loads better now :cool:
Been out polishing today so here are some updated pictures enjoy.
(http://img.photobucket.com/albums/v495/sharemaster/DSC00425.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/DSC00424.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/DSC00423.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/DSC00422.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/DSC00421.jpg)
I love Autoglym!!!
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About time I updated seen as the golf has been de stored for the summer :)
I fitted a new sump and rubber gasket and cleaned the oil through, tappets sounding a lot healthier now.
Also bought a FK strutbrace and fitted it along with g60 top mounts a few weeks ago.
(http://img.photobucket.com/albums/v495/sharemaster/P5020002.jpg)
Then today got the T-cut and autoglym out and redid it after the winter fade now getting back to been shiny :)
(http://img.photobucket.com/albums/v495/sharemaster/P1010043.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/P1010032.jpg)
Won a set of castelletes on the bay 15x7 so refurbing them and then putting them on to replace my bimmer rims!
More to come!
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the gearbox let go and made a big hole and a lot of noise
(http://img.photobucket.com/albums/v495/sharemaster/18022007281.jpg)
So I did the following!
(http://img.photobucket.com/albums/v495/sharemaster/17022007271.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/18022007277.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/22022007287.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/22022007295.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/27032007349.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/31032007355-1.jpg)
So then engine sorted I've moved onto the wheels and bodywork.
Got these wheels from Ebay and started stripping them back as they were corroding and looked awful.
(http://img.photobucket.com/albums/v495/sharemaster/07052007395.jpg)
I started polishing them up which started to make them look like this
(http://img.photobucket.com/albums/v495/sharemaster/13052007412.jpg)
and me like this
(http://img.photobucket.com/albums/v495/sharemaster/13052007406.jpg)
Then after a fair old while got them looking like this
(http://img.photobucket.com/albums/v495/sharemaster/25012008138.jpg)
Then realised I had 3 more still to do :lol:
Then got busy with a spraygun and got them like this.
(http://img.photobucket.com/albums/v495/sharemaster/13022008155.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/13022008154.jpg)
Now need to get some tyres on them and about 16 different locking wheelnuts and I'm good to go :)
Then next on the list is a full respray in the same colour and removing the smoothed boot :)
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Took a few pics of the wheels. Finally on the car :) need to sort out the centrecaps and then keep them clean and shiny all summer :laugh:
(http://img.photobucket.com/albums/v495/sharemaster/05032008174.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/05032008173.jpg)
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Well Fitted my Hot Tuning coilovers and slammed the car to the deck!
(http://www.monzasphotos.co.uk/Gallery/Huddersfieldvagapr08/album/medium/0001.jpg)
(http://www.monzasphotos.co.uk/Gallery/Huddersfieldvagapr08/album/medium/0002.jpg)
Then tonight I have taken her to be resprayed :) took all the trim and windows out and boot off and set off!
(http://img.photobucket.com/albums/v495/sharemaster/18042008225.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/18042008227.jpg)
More to follow as work goes on with her :)
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The Project begins a 1.8T into my mk2 Golf 16v
(http://monzasdetailing.co.uk/Blog/wp-content/uploads/2008/09/11092008413-300x225.jpg)
Audi Engine in an Audi
The project starts here the photo above is the Audi after a mild spanner wielding session to strip it down and get it out and on an engine stand, this is day 1 part 1.
(http://monzasdetailing.co.uk/Blog/wp-content/uploads/2008/09/110920084141-300x225.jpg)
The engine up close and personal
The lump, a 1.8 20v turbocharged Audi auto engine, code is AEB. It's an early big port version Mounted longitudally so the wrong way for the golf which is transverse and an auto box just for extra giggles.
(http://monzasdetailing.co.uk/Blog/wp-content/uploads/2008/09/11092008415-300x225.jpg)
Now the bumper and front end are off we can see what we have
notice the second rad fan is mounted to the engine and a viscous hub, it also has power steering which I don't have so the pump will need removing and the belt layout re routing to suit amongst other things.
(http://monzasdetailing.co.uk/Blog/wp-content/uploads/2008/09/11092008416-225x300.jpg)
The turbo!
This is the turbo it's a kkk k03 turbo the engine produces a factory 150bhp although it is capable of more power by remapping which will push it up to around 200bhp.
The Engine is out now and on a stand, I've stripped it, cleaned, re gasketed and replaced any broken or worn parts, I have got an AUG code inlet manifold fitted as the AEB one doesn't fit.
(http://monzasdetailing.co.uk/Blog/wp-content/uploads/2008/10/01102008455-300x225.jpg)
AGU Inlet manifold
As you can see, I decided to go against the current trend of polishing and chroming everything. I've gone matt black if it was on the engine and not black it is now matt black! black silicone hose and a dash of carbon fibre here and there. 1.8T mk2 Black edition! smile.gif
(http://monzasdetailing.co.uk/Blog/wp-content/uploads/2008/10/01102008458-300x225.jpg)
Black edition 1.8T!!
(http://monzasdetailing.co.uk/Blog/wp-content/uploads/2008/10/01102008453-300x225.jpg)
Black edition 1.8T!!
So hard to photograph! especially with a phone camera sad.gif
It's nearly at that point where I have to sit down and take the wiring loom apart, that should be fun!
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Well here we go again! The engine is out and it's back on axle stands once more. Some pics of progress so far and hopefully get the engine sat in this week to start figuring out the plumbing and exhaust stuff.
It starts like this
(http://img.photobucket.com/albums/v495/sharemaster/18T%20Swap/02012009517.jpg)
Your coming out
(http://img.photobucket.com/albums/v495/sharemaster/18T%20Swap/02012009519.jpg)
Bumper off
(http://img.photobucket.com/albums/v495/sharemaster/18T%20Swap/02012009518.jpg)
Front panel off.
(http://img.photobucket.com/albums/v495/sharemaster/18T%20Swap/02012009520.jpg)
Right now I can see what I'm up to.
take off the manifold
(http://img.photobucket.com/albums/v495/sharemaster/18T%20Swap/02012009522.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/18T%20Swap/02012009523.jpg)
Unfasten the exhaust and coolant, unplug the gearbox and out we come, one engineless golf took me about 3 hours altogether.
(http://img.photobucket.com/albums/v495/sharemaster/18T%20Swap/03012009524.jpg)
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This is where it begins fully 8)
The engine is in, well it was it's back out now ;D :D
(http://img.photobucket.com/albums/v495/sharemaster/18T%20Swap/11012009535.jpg)
Slight issue with the sump. I have a solution though I hope :)
(http://img.photobucket.com/albums/v495/sharemaster/18T%20Swap/11012009540.jpg)
Just changed the gear linkage from rod change to cable change and started to swap the pedal box over to the hydraulic version from a Passat GT to match the gearbox which has altered ratios.
So far so good couple of things are a pain to figure out but nobody said this was going to be plug and play and I do like a good challenge :lol:
09 feb 09 update
So to anyone thinking of putting an AEB into a mk2 golf here are the gotcha's I've come across so far.
Exhaust manifold and turbo hit the rear engine mount, currently deciding whether to grind a bit off so it clears it or use a mk4 golf transverse turbo and exhaust manifold, or mount the audi turbo on the mk4 Golf exhaust manifold.
Sump is far too big, have a cunning plan using a 16v steel sump and oil pickup pipe, need to check it fits and make an oil return hole for the turbo.
The AEB uses a nipple for the coolant feed from the block to turbo and the AGU has a 14mm threaded Banjo bolt.
The alternator fouls the throttle body think the mount needs changing over
The inlet manifold hits the front panel so a transverse one is required to make it work, which means you need a transverse fuel rail to match.
The angled oil filter housing from the AEB interferes with the front engine mount so a different one has to be used, I have an AGU one but it really doesn't fit, totally different.
The Audi has a second fan that runs from the alternator belt which confuses the belt issue, I have a VR6 water pump pulley to try and get it right.
The routing of water pipes on the block doesn't match after putting an AGU inlet manifold on + a few other bits. I have a full set of coolant hoses from ..... An AGU engine to try and fasten up.
Auto box = new flywheel and clutch to mate to a transverse engine. I have a Passat GT one with a VR6 clutch which bolts up ok.
Going to try and get a couple of days at it this week and get the block built up and hopefully drop it into the bay one last time next week :)
16th March 09
Bit of an update guys,
The engine is now in the bay, a mk4 golf turbo and manifold have been put on along with the mk4 coolant and oil lines to the turbo, 16v sump from a KR has been fitted and seems ok had to fit an oil return to it and hoping the driveshaft clears it :o
Finally found the oil cooler bracket I needed on a mk3 TDI and got a Mocal oil cooler kit for it to hopefully keep the temps down under the bonnet.
I have an ECU on it's way at the end of the month which is a new unknown unit but the spec list is pretty awesome such toys as progressive boost control, launch control, wideband support, traction control, switchable maps etc .
Radiator and intercooler pipework is next and hopefully my downpipe will arrive this week allowing me to get as much as possible plumbed in before the ECU arrives :)
Intercooler is from a new transit and seems to fit nicely behind the bumper so that should keep things nice and cool.
Elsecar in less than 4 weeks OMFG! :-X
3rd April 09
More work done recently, lots of messing about trying to get the coolant pipes to run properly and oil pipes for the turbo in, these are now sorted bar the shouting and my new intercooler arrived along with some silicone hoses, so I am now onto running and planning boost hoses and mounting the intercooler.
I had to put the grill on to check the centre spots still fit with the intercooler in place which has made me want to finish it soon. :)
(http://img.photobucket.com/albums/v495/sharemaster/IMAG0061.jpg)
16v Sump is now fitted and also has the oil return in. need to make a bracket to hold the alternator in a different position so it clears the throttle body.
Got some twin pot 280mm S2 brake calipers and carriers so building those up and just hoping they will clear the inside of my wheels :)
Got a bracket missing from the gearbox, need to go hunting around scrapyards.
ECU is delayed so not going to make Elsecar hoping to have it ready for Big Bang at the end of April.
(http://img.photobucket.com/albums/v495/sharemaster/IMAG0063.jpg)
25/04/09
Spent most of today in my garage and got a fair bit done. Bit of an update and some pics :)
I have got the intercooler and rad mounted up and plumbed in,
Intake pipe to turbo and outlet pipe are in place,
Coolant pipes are done bar a few jubilee clips,
Wiring loom is plugged in and nicely grommeted into the raintray ready for splicing into the ECU when it arrives.
Gearbox and rocker cover/inlet manifold are now black again,
New wheels are on the way to fit over my new shiny S2 brakes,
Things still to do.
ECU wiring and headlights horn etc
Not found a gearbox shift lever thingy yet, the hunt continues.
Need to sort the vacuum system out and plumb in the dump valve etc.
Some fuel lines to make up,
Brake lines to sort out,
Clutch to fill and bleed,
Brake hubs need rebuilding with new flange and bearings.
Calipers need fitting to rebuilt hubs,
Driveshafts fitting to gearbox and hub,
Fuel putting in as it was nearly empty,
Dash to put back in,
carpets and seats to go back in,
new wheels on,
MoT and Tax
DRIVE!
Put the front back on, looks like a golf again :)
(http://img.photobucket.com/albums/v495/sharemaster/24042009583.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/24042009584.jpg)
(http://img.photobucket.com/albums/v495/sharemaster/24042009585.jpg)
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Updatez:
The brakes are fitted on one side now the other side needs a driveshaft or inner cv :(
Audi S2 280mm twin pots :smug:
(http://img.photobucket.com/albums/v495/sharemaster/07052009609.jpg)
They just fit under my Estorils :)
(http://img.photobucket.com/albums/v495/sharemaster/07052009613.jpg)
Exhaust and downpipe are wrapped and connected to the engine and my old stainless system. Pretty much converted now just need an ECU some jubilees and a master cylinder and some brake line fettling :)