GolfGTIforum.co.uk
Model specific boards => Golf mk3 => Golf mk3 gallery => Topic started by: dansmk3 on 08 August 2011, 11:18
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Well, its as good a time to start this me thinks.
As most of you know i have been having major dramas with the old girl. cam belt going, reconditioning the head giving it a good clean up and getting her running again. then 4 days later the crank pulley shearing off. so instead of paying out around £300 notes in parts to replace the crank and various parts to get the lump running again, i decided to go down the VR conversion route. Thanks to Wayne for finding the lump on ed38 for me.
First off, here is the old girl in question.
FRONT
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG00104-20101029-0950.jpg)
REAR
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG00053-20100718-1635.jpg)
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The first hurdle was to get the lump which has come with all ancils, loom, ecu, everything needed really. which i decided to collect myself. got the engine home and due to lack of space had the lump in my boot and now i have a boot full of oil, spare wheel covered etc etc :angry: but it was my only option lol
first thing to do for the build was to strip the bay. so front bumper off, slam panel etc
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20110806-00042.jpg)
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20110806-00043.jpg)
nothing too chalenging on getting these parts off, thats all to come as the cuts on my hands and arms can confirm :laugh:
once this had been done started disconnecting pipes, cables, and things that werent connected to the engine, so it could slot straight out.
whilst the car was up on stands, had to disconnect the driveshafts, which was not pleasant. 2 of the spline drived bolts rounded off on both sides, so had to get a bigger drive, extension bar and a hammer to make a new way of getting it out. BEAR IN MIND THAT THERE IS NOT MUCH ROOM!!
next was the exhaust this was also a pig, the bolts on the sleve between the cat and centre pipe were well corroded so i wasnt going to get anything on that, looked down towards the rear silencer and pretty much the same story, so 1 mate and a hacksaw later and exhaust was free.
had to pull heatshield out from where the cat sits to get to the gear linkage out and get the new hydro one in.
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20110806-00044.jpg)
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On getting the engine out, this was a doddle, apart from the rear drivers mount as i kinda left it connected to the engine :laugh:
once it was out though had to change the res for the brake fluid so that i can run the hydro clutch
RES
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20110807-00050.jpg)
HYDRO CLUTCH
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20110807-00049.jpg)
thanks to Benvictors for sorting me out with said item and the new pedal box which i needed :afro:
now this is where the serious fun begins. had to disconnect the steering column, undo 2 nuts which are pretty much impossible to get to behind the master cylinder, and undo the 4/5 nuts which hold the pedal box in place.
now to get the steering column to unclip itself from the pedal box was the biggest b1tch in the world. 2 shear bolts which clamp the column down on the car took me and my mate 2.5hrs to get them out with a drill, hammer and flat headed screwdriver. as soon as that was done we were laughin
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20110807-00048.jpg)
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Now was time to sort the loom out, ecu came out and had to trace my old loom out and start to disconnect at the back of the fuse box.
OLD LOOM
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20110807-00045.jpg)
NEW
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20110807-00046.jpg)
on connecting the new loom in, the 3 main white plugs have been connected, and a couple of others, however there are a few that dont connect anywhere. can only hope that this is becuase i dont have certain things that the donor did.
and this is where i am upto at the moment. as the shear bolts really took its toll on us :laugh: and really cant wait to get the lump in. but am also waiting on a few things that i need first. so hopefully a couple of days and there will be one hell of a progression! :smiley:
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loooking good pal
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cheers mate, my hands and back beg to differ :laugh:
all i got to do is work out where all the ancils go, get the bolts for the box, ht leads and start piecing together.
i take it this box would take a kind of gasket like my 8v box did? on the 8v it was a small thin piece of metal which had 2 bolt holes and covered prob 1/4 of the box
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Gasket hwere, have you a pic ?
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ill sort one, when i took the box off the 8v a smallish piece of metal came out too
i just didnt think the box would bolt on metal-to-metal, maybe it does lol
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Cracking progress :afro:
I got lucky with my shear bolts and mole grips worked.
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Cracking progress :afro:
I got lucky with my shear bolts and mole grips worked.
mate i tried that and the shear bolts just fooked em off :laugh:
ill get a couple of little pics of em in a min. really wanna crack on with it today but not really much i can do on me jack jones :cry:
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here is the state of my shear bolts
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20110808-00055.jpg)
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^^ :shocked: :shocked: guess I was really lucky then.
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yup :laugh:
wayne do you know where i can find out what ancils go where mate? iv got a few on where i think they go but i just want to make sure
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yup :laugh:
wayne do you know where i can find out what ancils go where mate? iv got a few on where i think they go but i just want to make sure
Sign up to: www.vagcat.com it is free.
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Alright Dan, cracking progress mate. The Gasket your talking about is just a sort of dust cover that sits at the bottom of the box. The gearbox sits a bit lower than the sump and there is a big gap without it, so it would allow road dirt and water up if not fitted. If the VR one is fitted in a similar way but you dont have the cover, I'm sure you could fab up something that would suffice mate. :wink: :smiley:
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Alright Dan, cracking progress mate. The Gasket your talking about is just a sort of dust cover that sits at the bottom of the box. The gearbox sits a bit lower than the sump and there is a big gap without it, so it would allow road dirt and water up if not fitted. If the VR one is fitted in a similar way but you dont have the cover, I'm sure you could fab up something that would suffice mate. :wink: :smiley:
the one out the 8v box does fit, kinda. its a couple of mm too long at one end so i might just snip a little bit off then bolt together!
i was going to give the bay a good clean and tidy up but dont think i have the time lol
and cheers sean there still a fair bit to do, however we have broken the back of it, just got to fit all ancills to the lump, change drivers rear mount, fit box to lump and get it all in. tempted to change the clutch plate and flywheer? hmmmmm lol
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Getting it out is the easy part! :laugh: It should be ok as its all still fresh in your memory, even though it is a different engine! Mine was out for about 8 weeks so had a job trying to remember what everything was for and where it all went! Its a tight squeeze getting an 8v back in with the GB on, let alone a VR though! If you can put it in without the GB I would advise doing that, and then put the box on after as it will probably make life a bit easier in the grand scheme of things. I kept getting the driveshafts stuck underneath, and was a pain in the arse lining up the manifold without the pulleys catching one side, or gearbox catching the other. Good luck though! :evil:
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Right time for some updates as we all like em lol
Full set of coilovers have been ordered.
Thanks to Mk3gti16v for sorting me out with the hydro clutch pipe from the res to master cylinder
Ordered some german plate surrounds also.
Does anyone know if the drivers engine mount bracket off the 8v is the same as the VR?
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Sweet. :cool:
Looking good, good process. I gave up on my sheer bolts in the end, gonna have another crack tomorrow, tried punching and punching and punching.
Will resort to cutting them out I think, haven't tried it on the car I'm keeping though!
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Mate sometimes you get lucky! This time I didn't! Lol!
If you aint doin anythin on saturday mate pop up! Could do with a third pair of hands getting the lump in lol
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right, looks like it aint getting done tomorrow as i need different engine and gearbox mounting brackets.
screwin now! :angry:
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right, looks like it aint getting done tomorrow as i need different engine and gearbox mounting brackets.
Engine brackets are different, main rubber mounts are the same.
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i just found that out lol
had to change the drivers rubber mount
anyone know where i can get these brackets as i am in dire need!!! lol
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i just found that out lol
had to change the drivers rubber mount
anyone know where i can get these brackets as i am in dire need!!! lol
Scrappy maybe
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gotta hold out for the scrappy, phoned a few last week and they didnt have any vr's in.
wayne, are the 16v brackets the same? or are they different?
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gotta hold out for the scrappy, phoned a few last week and they didnt have any vr's in.
wayne, are the 16v brackets the same? or are they different?
16v would be different, give me 10mins and I will check.
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Hope this helps :smiley:
Item 10: 1H0199273D, front / manual- gearbox: AAA, all other engines are listed with a different bracket, 16v (ABF) is different again.
Item 21: 357199354J, right / manual- gearbox: AAA, same as above.
Item 27: 357199353A, left / AAA,ABF,1Z, AFN
(http://i125.photobucket.com/albums/p51/jmfangio5/199200.png)
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ill admit that diagram did kinda throw me a little. as thats the diagram i got on ETKA
there is a bloke on ebay with the full set but he aint back until next weekend! typical aint it!
just want my motor on the road already :cry: :cry:
cheers for the diagram mate :smiley:
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No probs :afro: good luck in your search.
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No probs :afro: good luck in your search.
cheers mate, iv been messaging people selling vr lumps and they dont wanna sell the brackets! assholes lol
some people ay? :rolleyes:
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Thanks to Mk3gti16v as my hydro pipe arrived this morning!!
:afro:
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yeahhhhhh!!! thing are coming along. I love white vr's
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just gotta wait for the engine mounting brackets now. iv managed to source the rear one but need the box and front ones now!
i know good things come to those who wait but this is takin the pi55 now :laugh: :laugh: lol
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well what a turn up for the books.
been on ed38 and found a bloke breaking a vr, got the gearbox and front engine mounting brackets along with the cover plate for the gearbox, £19!! well i paid £29 as i asked for next day special delivery!! well happy here :smiley:
and to top it all off i have just recieved this through the post
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20110816-00058.jpg)
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20110816-00060.jpg)
now all i have to do is work out how to set them up :laugh:
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Easy to set them up, front ones around half way, rears fit as they are, then see how it sits.
Don't forget to copperslip all the adjuster threads before fitting, will save them seizing up.
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Easy to set them up, front ones around half way, rears fit as they are, then see how it sits.
Don't forget to copperslip all the adjuster threads before fitting, will save them seizing up.
cheers mate, thats easy enough then lol! iv got plenty of copper slip! defo cant be doing with them seizing up like!
i know alot of people will probably comment saying i should have gotten more expensive coilovers etc etc but these are all that i could afford and im happy never the less! lol
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Got all my mounting brackets through the post today,
Gearbox has been attached although I'm going to buy all new bolts for it.
Got the front mount and rear mount on, but the gearbox mount is giving me a bit of grief. On looking at the thread inside the holes on the gearbox it looks rather corroded, soguess I'm going to be buying a tap and dye set to rectify this problem
Went to connect the water pipes and they are fubard, o ring gaskets are shot and doesn't look like a tight fit so new ones will be ordered also! - don't help when they are covered in sealant neither! Alarm bells were ringing charlie ll
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Went to install the new suspension yesterday and the nuts at the top of the suspension are totally corroded so am going to have to think of another way of getting these out.
so in the meantime i decided to do this:
(http://i1224.photobucket.com/albums/ee372/dj_madman/27082011109.jpg)
Thats right iv got the old girl in. im really surprised and pleased at how much space there is behind the lump compared to the 8v, goes to show how far forward the vr sits.
then it was time to stick my stainless manifold on
(http://i1224.photobucket.com/albums/ee372/dj_madman/27082011110.jpg)
Put all injectors in and the fuel rail on. then got the wiring sorted for the rail, went to put the inlet manifold on and it wouldnt fit and then realised that where i had the plugs on the injectors facing upwards they needed to be facing towards eachother, once i had figured this out it was time to get the powder coated intake mani on
(http://i1224.photobucket.com/albums/ee372/dj_madman/27082011111.jpg)
so what i have to do next is work out all the coolant hoses and where each one goes, and the same goes for the wiring. i have noticed one problem, my new radiator fan motor has a massive oval copnnection for it, where on my 8v one it was a small rectangular connection, so im thinking would my old motor run the new fan? or is it a simple swap of the plug on the loom? hmmmm lol
well as you can all see it is getting there it is slowly coming together just gutting she aint finished yet. but i am having fun looool
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Excellent progress.
Your fan motor should be fine :afro:
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Excellent progress.
Your fan motor should be fine :afro:
Sweet, ill get that swapped over with the suspension tomorrow! Iv been told the vr has 2 fan speeds that's why I was dubious! Lol, and cheers wayne! She certainly is starting to take shape now! Just want to unleash the fury hahaha
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Id fit the Vr6 fan mate, and twin fan rad set up
On the VR the fan is on most the time
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Id fit the Vr6 fan mate, and twin fan rad set up
On the VR the fan is on most the time
+1
they love a bit of heat. Mine has a 70c thermostat :wink:
http://dubpower.co.uk/VR6%20parts.HTM (http://dubpower.co.uk/VR6%20parts.HTM)
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Id fit the Vr6 fan mate, and twin fan rad set up
On the VR the fan is on most the time
I meant to say im keeping the vr fan setup (twin fan) and rad, but as my connection for the fan is not that same i was going to swap the motors, so the motor out of the 8v fan and stick that on the vr fans, or should i just get that part of the loom?
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keep it all as it was on the VR
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furry muff, best be looking for another fan loom lol
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in fact what part of the loom is the fan connection on? would it be the main harness? or on the light loom?
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i know this car lol ill be up soon when its finished to save oil on my mits :wink:
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i know this car lol ill be up soon when its finished to save oil on my mits :wink:
cheeky fack! could at least offer to help now all the hard work is done lol
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i know this car lol ill be up soon when its finished to save oil on my mits :wink:
cheeky fack! could at least offer to help now all the hard work is done lol
yeah ill come to watch the test drive if the engine dont fall out ill go for the 2nd journey thanks ;) anymore pics ?
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that engine is going nowhere! lol
no more pics as yet, will do once iv dropped it! hopefully that will be by the end of today
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WOW its been 4 months since i have done anything on my conversion!!!!!!! im appauled! :sick: lol
well the conversion got put on hold since September as i could not source one part that i needed to complete.
so my decision was to source a cheap enough running VR6, use it while the cold months were here and then start all over from the donor.
just before Christmas i managed to find a P reg VR AUTO HIGHLINE on the bay with 9 months mot on her and only 88k miles all for just over £500
All the leather is in immaculate condition. :grin:
Here are a few piccies
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20120106-00031.jpg)
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20120106-00032.jpg)
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20120106-00033.jpg)
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20120106-00035.jpg)
(http://i1224.photobucket.com/albums/ee372/dj_madman/IMG-20120106-00036.jpg)
hopefully in a couple of weeks ill be starting to finish off the project. but for now i need to get all of my parts ready for the manual conversion, clutch, flywheel and gearbox.
the chains need replacing as they are starting to rattle, so they will get done, and the head will be getting ported and polished.
new brakes will be getting put on also. can anyone confirm that when upgrading my 280mm brakes to the 288 all i need to swap over is the carriers for the calipers?
one thing i cant wait for is it being a manual as the autos drink far too much lol
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Interesting project, bet you cant wait to finish it...
what are you going to do with the vr when you've finished with it?
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hi mate, no i cant wait for it to be finished lol! been a bit of a ball ache to be fair.
im going to be breaking the VR as much as i can to get back a little bit of money that iv shelled out and to help fund the ever so tempting turbo thought iv been having since starting this lol
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turbo thoughts...we all have them...
Il keep an eye out for some bits when you decide to break it
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How much cash/help do you want for. The leathers? :grin:
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which you braking the Highline or the GTI ?
Confused haha
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can anyone confirm that when upgrading my 280mm brakes to the 288 all i need to swap over is the carriers for the calipers?
You need to change the calipers as well.
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which you braking the Highline or the GTI ?
Confused haha
I'm going to guess the Highline, that's the impression I've got anyway :smiley:
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I'd keep the highline and convert to manual
Don't see point in breaking it, looks a better car
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can anyone confirm that when upgrading my 280mm brakes to the 288 all i need to swap over is the carriers for the calipers?
You need to change the calipers as well.
aha cheers Wayne
turbo thoughts...we all have them...
Il keep an eye out for some bits when you decide to break it
no probs mate
How much cash/help do you want for. The leathers? :grin:
leathers are being kept im afraid! they are in bloody good condition also, no rips in them! the rears dont even look like they have been sat in
which you braking the Highline or the GTI ?
Confused haha
alright kels? the vr ill be breaking, and obviously all other gti bits that i wont be using.
all in all im quite happy knowing that i now have absolutely everything that i need! :D
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the sills on this one are all rotten, and mine aint. and you dont see many white VR's so thats another reason why i would rather keep the gti shell.
dont get me wrong it would be alot easier but there aint no fun in it then looooool
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Nice project buddy! Keep it up :)
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I'd keep the highline and convert to manual
Don't see point in breaking it, looks a better car
This, half the work is done already.
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the sills on this one are all rotten, and mine aint. and you dont see many white VR's so thats another reason why i would rather keep the gti shell.
dont get me wrong it would be alot easier but there aint no fun in it then looooool
furry muff
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Yea fair play if theirs bad rot
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yeah its not a nice look and you can see that it has had a bodge weld! either that or the rust is forcing the existing weld upwards lol
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god build. did u ever put the coillies on?
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god build. did u ever put the coillies on?
yeah coilies are on. a neighbour of mine had a 12v impact gun which got the originals off.
im just busy getting all parts together now ready for eveything to go on now.
so hopefully when this snow and cold weather has buggered off i can continue lol