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Model specific boards => Golf mk2 => Golf mk2 gallery => Topic started by: jv on 14 May 2006, 19:25
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here you go :)
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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:
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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!
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whoa i meant the mk2 is going to rtts- the Escart is only gonna be driven at night in case anyone sees me..
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arses, if only this rain would stop i might get something done...
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Picked up a new speedo cable today from GSF...twenty seven quid!
:cry:
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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:
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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:ÂÂÂ
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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:
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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:
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Took gearbox out again...underside of car was covered with oil after only a couple of days, even on the wishbones!
Realised the gearbox input shaft seal has gone, (which probably means the crankseal was ok..) and all the fresh gear oil i put in had just sprayed out into the bell housing/clutch/world. Fortunately had picked up a Sachs 16v clutch of Feebay which meant i could put my 16v box back in. The Sachs clutch looks and feels better quality then the old LUK one. Both 8v and 16v friction plates are the same diameter though which is a surprise.
Before i did all this work it was pretty hairy on corning- you could feel the front end was unsettled but now it has no clutch slip, new bushes, track rod end and awesome Toyo Proxes T1s it is :laugh: :laugh:
NEVER has a vehicle owed me so much hard driving...
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...Speaking of which, this morning i had to drive from Tiverton to Minehead on the brilliant A396 (mentioned in Evo mag as one of the best driving roads in the UK). Its an awesome mix of long straights,wobbly bits, tight corners, peaks, troughs, wooded bits- the works.
Jeez is the mk2 amazing now- i met 6 cars in 25 miles, none of which held me up for long. Some kiddie in an AX GT kept sitting right on my arse through the 30/40mph limits and then seemed to repeatedly reverse really really fast when we hit the nationals :rolleyes:
Did get some serious brake fade though despite Pagid Fast Road pads and those (apparently useless) 16v chin spoiler ducts.
If anyone can get to J27 M5, drop me a pm and i will give you a tour!
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:laugh: :laugh: :laugh:
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Have now decided i prefer the 16v box to the 8v, yeh not so good on fuel but much quicker response at motorway speeds, she fair thunders along now.
The GIT hasnt broken down for a while now, using it everyday too so all good...hoping to pick up some of them motorbicycle carbs when i get paid for another month of screwing around with my car :smiley:
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Had to do a front wheel bearing over the weekend- was fine 2 weeks ago and then started rumbling this week. Managed to get it out (defo needed that bearing press and the gas tho!) and a new one sorted the problem. Did the camber+ tracking at the same time so now shes a proper flighty thing, turn in is ace and feels great with new bushes. Its too soft really given its grunt but thats all part of the fun...
Off to Majorca for 2weeks on the 8th- if i come back with any spare cashola its definitely going on carbs.
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Fitted a brand new cam chain and naturally have had a right old mare with the timing..
Also one of the junctions on the oil cooler broke off during job- it looks like its been leaking slightly for ages but still thats thirty plus squid i would rather not have spent :angry:
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Update....
After eventually timing the GIT up with the timing chain gears and the flywheel indent, but ignoring the bottom pulley and sprocket marks ( :huh:) the old girl ran fine.
Wouldnt idle though.
At all.
Swapped ISV...no change
Checked/swapped all sensors...no change
Out came multimeter and all is well with wiring etc...
Figured it could only be the ISV controller behind the centre console.
Which is obsolete and therefore £300 plus from VAG...
After much phoning around i bought one off Feebay which has yet to arrive :angry:
All flippin annoying, especially as my tax expires today :cry:
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R1 carbs are a go!
Having finally got the GIT to run again (timing joy) its gonna cost me ninety quid to be road legal again :angry:
Valver is now SORN as i now have a Passat as a daily driver which gives me an excuse to finally do the carb conversion. Also the Passat has a cable change box and handy bits like a matching pedal box which it may well sacrifice at some point in the future..
See my post in parts for sale!
I am going to knock up an inlet manifold for the bike carbs and also have a crack at a tubular exhaust manifold and naughty exhaust too. My mate has offered the use of his fabrication shop on the promise that when its finished he can rag it round some track days and midnight Devon rallies..
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I now have a lovely set of Mikuni 40mm downdraft R1 carbs :laugh:
And the GIT now has a nice clean engine bay, with none of that new-fangled fuel injection nonsense...check out feBay for 'VW Golf GTI 16v 50mm Inlet Manifold, Injectors & more!'
Unsurprisingly the carb spacing doesnt quite match that of my 2.0 6a head so i will to make a manifold to suit. The carbs are all separate with a common choke slider and coupled throttle shaft- either i extend these and space the carbs so the inlets are perpendicular or just make up some bent ones. Also the main coolant feed into the head needs rejigging to miss the carbs and the dipstick is going to either get shortened or ignored.. :tongue:
The carbs have a remote idle thumbwheel and a throttle position sensor (apparently a good thing for those clever enough to build an ECU :huh:) and are very compact and very nice!
Will sort out some overdue pics
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(http://www.freemyimage.com/ims/pic.php?u=1461m4PhS&i=15260) (http://www.freemyimage.com/ims/pic2.php?u=1461m4PhS&i=15260)
(http://www.freemyimage.com/ims/pic.php?u=1461m4PhS&i=15261) (http://www.freemyimage.com/ims/pic2.php?u=1461m4PhS&i=15261)
(http://www.freemyimage.com/ims/pic.php?u=1461m4PhS&i=15262) (http://www.freemyimage.com/ims/pic2.php?u=1461m4PhS&i=15262)
(http://www.freemyimage.com/ims/pic.php?u=1461m4PhS&i=15263) (http://www.freemyimage.com/ims/pic2.php?u=1461m4PhS&i=15263)
(http://www.freemyimage.com/ims/pic.php?u=1461m4PhS&i=15264) (http://www.freemyimage.com/ims/pic2.php?u=1461m4PhS&i=15264)
(http://www.freemyimage.com/ims/pic.php?u=1461m4PhS&i=15265) (http://www.freemyimage.com/ims/pic2.php?u=1461m4PhS&i=15265)
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Righto...
-Have decided to make a mild steel inlet manifold to start with, will replace it with an aluminum one once it rusts away :rolleyes:
-Made a card template and marked out the inlet ports and fixing holes..glad i kept a spare head and inlet tract handy!
-Realised that squashing the end of some 40mm OD tube gave a flat-sided oval section that matches the ports perfectly.
-The carbs are spaced much closer together than the inlet ports- if the carbs are centred on the head, none of them line up so...
Taking the carb assembly apart and spacing them to fit the inlets will defo create only more problems so i am going to make the manifold offset- the four Mikunis share a common fuel rail, throttle shaft & choke.
I reckon a small piece of 40mm OD tube squashed as above welded to the inlet plate (some thickish mild steel. Though this may corrode the head by electrolytic wotsit the spare head has new stem seals and i reground the valves too so it would be a good replacement) Then some short angles bits to suit and then 4 short bits onto which some silicon tube will sit to hold the carbs. There is plenty of space under the bonnet as i can sort out the air filters afterwards.
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Spoke to Bogg Bros today about rejetting the carbs...
For £60 exc postage they will rebuild them with the correct jets and guarantee them to be fully driveable when fitted.
They recommend a rollling road session for fine tuning which is fair enough.
Cant argue with that- saves my lovely little mikunis from my big fat hands.. :grin:
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(http://i28.photobucket.com/albums/c210/shonadog/mk1.jpg)
Well thats the end of my Mk2 project...£250 for a MK1 GTI with a TSR 285mm disc conversion :tongue: