Dan_GTi8v, 20vt project

[Mr_Orange]

Cracking read.  Keep up the good work!

[Dan_GTi8v]

Cracking read.  Keep up the good work!

cheers

Update coming today, been taking a few days to upload all the pics photobucket is taking an age to upload 

[Dan_GTi8v]

Guess I'll do the battery relocation first. I did this and the catch can at the same time over 2 or 3 days, but some of the pics are still uploading.

I didn't get a pic of all the bits and pieces I used, but basically its just 5 meters of welding cable, around 0-1 gauge (32mm squared) a positive and a negative battery clamp, a junction box, and various sized 8mm ring terminals

So, first off I routed the cable from the engine bay through the car and into the boot. Access to the grommet in the engine bay isn't great and I did try for a while to get it off but in the en I just cut through it and fed the wire through, needs tidying up later


I took all the interior trim off that needed to be removed, pulled back the carpet and fed it through up to the rear seats, following the wires that were already there through a tunnel thing under the seats and into the boot, then ran it around the edge of the boot under the carpet and up to the box. I put the terminal on later but no pic of that





Also uncovered this thing, anyone know what is it?


Next up was the negative wire. I pulled back the carpet around the box and wheel arch looking for a good spot. not really many options tbh, basically either through the arch which would mean having to bolt through the exterior of the arch which I didn't want to do, or just behind the arch as shown in the pic where I could get behind and so have both nut and bolt on the interior




and here it is in the box with the terminal attached


so that's all the new wiring routed and ready. Next up was fitting the junction box and fitting the new 8mm terminals onto the old wiring. original trminals are something like 6 or 7mm, just to small for the junction box which was a bit annoying  So I set to cutting the ends off and fitting the new terminals. I didnt get any pics as almost as soon as I cut the first wire it started to lightly rain and I started panicing as I now had a car that couldn't be moved 

Pretty straight forward, cut the old terminals off, crimp on the new ones. Also as the old battery terminal was grounding the engine block to the bodywork, I had to cut the negative terminal off and ground the engine directly to the body. I used the original grounding points under the battery tray, there are 2 under there but I only used 1 and used to other one to bolt the junction box to. I mounted it onto a block of wood so I could angle it the right way without the other wiring getting in the way



and thats pretty much it for the battery, tidied a few things up but thats all the work done. here it is sitting it ins nice new cosy home in the boot away from the cold 



next up catch can install

[Dan_GTi8v]

OK, catch can install!

in addition to the bits already posted before I purchased some 15mm id hose, a plastic 19mm T piece, and a box of jubilee clips, so I now have this lot




First job pull out the old pcv pipework.

It runs from this outlet in the oil filter housing held in with a clip that you just pull out towards you (don't lose the O ring),



up to the notorious for breaking Y pipe pictured here (mines broken as you can see)



then that leads to the 'hockey puck'



There is also a small outlet just behind and to the right of the dipstick held on with a pain in the arse one time use clip. Pull this off and cap it as its just a vacum source for the pcv system. If you have no caps just cut the hose and cable tie a bolt into the end of it.



Undo all these connections and pull it all out. you need to keep the 2  pieces in the following picture, forget the T piece and the copper pipe, that plan backfired  just keep the filter housing L shaped pipe and the hockey puck




keep these bits


Pictures for the rest of the install are not great as this is the same time like in the above post that it started to rain, so I was moving fast.
Its a pretty simple install, You want to use the the original L pipe from the filter housing and fit a length of 19mm pipe onto it, this then runs to the T piece. From here the pipe splits, one way goes to the can and the other goes to where the original Y pipe was fitted. that's one side of the can install done. the other end is even easier, just run the pipe from the can to the hockey puck, and fit the puck back into its original location

The reason for the 15mm id pipe and reducers is that my can only has 15mm inlets so I had to reduce the 19mm down to 15mm (I actually used 16mm reducers and pipe as I couldnt find 15mm, but meh it has the same affect)

Hopefully you can make sense of that from the final install pics





All I did after this when the rain stopped was push the last few pipes on properly and stick some clamps on them. I'll probably lengthen some of the pipes at a later date so they can be run under some of the other stuff and not look such a mess, but until after the mot im not gonn throw any more money at it 

cheers

[Seanl]

That thing you were asking about is the seat belt pre-tensioner. Its attached to the buckle and on impact, fires a clip through the hole in the buckle to stop it ripping out. Good work so far, be good to see the finished article!

[Dan_GTi8v]

Passed MOT yesterday woohoo, had to buy another lambda as the wires were rubbing on the driveshaft which caused a fail on the lambda reading all good now though

I've decided to remove the cold side dv kit as its gains are next to nothing go gonna flog it for some cash 

Just gonna be tinkering now probably untill the new year, cant really afford to throw any more money at it for a while
I've been getting a pressure drop code pop up every now and then so gonna be looking for a boost leak, may take this opportunity to redo some of the pipework especially the passenger side now the battery is gone, make it more conventional routing. Also read the T bolt clamps are a bit sh!t and can cause leaks so will replace them with jubilee clips (there cheap enough  )

Writing all this is making me wanna spend money lol so I'm gonna stop

[tech1889]

Great progress now will look sweet once all tidied up 

[Dan_GTi8v]

Started fitting the new TIP today from creation motorsport, didnt go so well though as it gets dark so goddam early now. managed to get it on while nearly crushing my hand in the process, dunno how most mk4 people do it but I'm guessing there's a lot more space than there is in the mk3! Hoping to finish it off tomorrow along with some other bits and pieces so should be a pic update tomorrow with a relatively tidy engine bay and also how the exterior looks atm as I haven't had any outside pics for a while

also going to fit some boot struts to the bonnet and get rid of the awful rusty lifters I have fitted now, and fit some new rear bump stops. Exhaust needs looking at as well as it hangs real low and wonky at the back

[tshirt2k]

You could have at least chose a better way of getting the cable from the bay to the cabin. There are better access point to choose from without cutting into the side of that bellows.  You could also do with soldering those crimped connectors for extra strength and conductivity.

[Wayne]

You might be better to get a vented battery at a later date.