Dan_GTi8v, 20vt project

[Dan_GTi8v]

OK, pics so far as promised. Didnt get much done today due to work and had to scrap the old engine, got £7 rofl, better than nothing though needed shot of it asap



Closer look at the soon to be mullered 2.0 8v


Bumper off


Radiator off


Gearbox out after a LOT of F'ing and blinding!


Here its lifted on the hoist but the manifold is still connected, This is what we spent most of the day trying to remove, in the end we just grinded it off lol


Here its lifter properly and all seperated


And finally here it is in the back of the land rover!



Now for the new beast! Its an AUM from the mk4 GTi, all the sai n112 n249 and evap has been removed and forge blanking plate fitted, but here you can see it still connected. Can also see my new DPA box in the corner


And heres my first job for tomorrow, trying to remove the old and fit this new ABF cable shifter.



Other jobs for tomorrow include bolting the 02a starter to the box, changing the clutch for the VR6 one and fitting an abf flywheel, trying to somehow bodge on the mk4 pedal, and trying to lable up the loom ready for when we drop the aum in (planning for saturday)

[VR6_Wherry]

Finally some pics! 

Good work so far, we want more pics and lots of em with this build. good luck dude

[LazyLunatic]

Nice bud, glad to see you've made a start on the car

You keeping the aircon?

Piccies ftw

Let me know if you need anything bud

[Dan_GTi8v]

Just on a break atm lol .Thx for comments

LL yeah I'll be keeping the aircon compressor connected but wont be rigging it up just yet, all the inside stuff is already there but I had to butcher the old pipes a bit to get them off so i'll be getting some new ones at some point

All I've done so far today is cut out the old throttle pedal and fit the clutch master cylinder. Didnt take any pics of this as its fairly straight forward but I'll get some later when I decide how I'm gonna fit the mk4 pedal, also need to go down to halfrauds and get a torx bit for the new clutch

Cant remember what else I was gonna do lol but I'll take some pics of it anyway if I remember

[Wayne]

Don't forget to fit a new receiver / dryer to the air con system when you rebuild it.

[Dan_GTi8v]

is that the can that sits in the front bottom corner on the drivers side?

Took a few pics of the new forge dv that I got after breaking the old plastic one, and a couple of other bits and pieces, but left the camera in my dads garage

Fitted the new vr mounts and pulled all the carpet and stuff out the drivers footwell to investigate further about the mk4 pedal, will get a better look in the light and see what we need to make up to mount it. Also need to go back to halfrauds and get a refund for this torx i bought lol its the wrong thing, I need a 12 point spline bit but need to look up what size

[Dan_GTi8v]

OK progress for today

1.8t with the SAI n112 n249 and evap removed, lookes a bit tidier


And heres the pile of crap I removed from it


Managed to break the top off the diverter valve in the process


Sounds like a good time to get a Forge 007p!



Next I started work on the new engines clutch and flywheel setup, needed an M6 12 spline socket to take the old clutch plate off, ended up buying a set for £16 with included 7 sockets M4 up to M14 which was a good price I think, and also lucky as after I got the clutch off I needed an M10 spline  to get the flywheel off. No pics of me taking it off but got some of the new flywheel and new clutch kit

Before


After a good clean


New Sachs clutch kit


I managed to get the flywheel on but couldnt get the clutch on as I need some new bolts, the AUM bolts were too short to reach the thread on the ABF flywheel.

Tomorrow could be the day the engine goes in! Though not sure as we may need to move the brake servo to fit the bracket for th new throttle pedal, and we wont have the bracket made up untill sunday.
Other jobs for tomorrow include removing the old cat, dropping the old shifter and fitting the new cable shifter, fitting the clutch if I manage to get new bolts, and depending how hard it will be moving the servo with the engine in possibly dropping it in!

Hoping to get a lot done tomorrow

And after looking at the post preview, before anyone says it, no it isnt a real Monet in the broken DV pic 

[Dan_GTi8v]

OK, no engine dropping today, but did get some other stuff done.

Made up a template for the throttle pedal which will be made tonight, removed the cat, swapped over the shifter for cable, and trial fitted the new downpipe. Also spent ages getting some stones out of one of my drive shafts as it dropped down on the stones while we were pushing it back 

Also had to bodge up a kind of bracket to hold the shifter in at the front as its a slightly different design. May get some more pics of progress tomorrow if I remember

Oh and fitted a new dipstick guide as I snapped the old one 

[Dan_GTi8v]

ok, progress has been made! Left the camera at the garage so no pics from today but have a few from the last couple days

16v cable shifter in place, with a bracket bolted at the front to stop it dropping down, 8v had a single bolt here but the 16v is slightly different design, may change it b4 i finish up but it does the job for now


and here's what I've been doing for the most part since last update. Wiring! as it stands now I have all the old wiring out of the way, whats being kept has been intergrated with the new loom and its all in, taped up, and tucked away nicely. but this was it yesetrday morning


Also what I dont have pics of is the pedal bracket I've made up. its pretty good if I do say so myself! Pics are on the camera but as said I left it at the garage so i'll try and get them uploaded tomorrow. I've also taken out all the crap thats not needed on the aum (throttle cable clutch cable ignition coil and some aircon bits and pieces) and fitted the new hydraulic clutch master cylinder

First job of the day tomorrow is to go to VW and pick up the flywheel and clutch bolts I ordered and also a new brake pedal position sender clip which I snapped when removing the servo. After the servo and brake master cylinder are back on and pipes are secured I'm pretty sure I'll be set ready for the engine to go in, then I get the fun job of trying to work out where everything goes!

Oh and I also had to order a new radiator fan control relay as my current one is a 2 plug aircon unit, but new loom has the plug for non aircon. Still deciding wether I'm gonna mess about with aircon at a later date or not

And thats where things stand so far

Bring on the trumpets! tomorrow!

[Dan_GTi8v]

Proper preparation prevents piss poor performance!

I didnt have the right tool for the new clutch bolts and shops were closed by the time I realised so nont engine dropping today, its 100% going in tomorrow though

Heres the new pedal bracket I made up




Its a pretty snug fit, havn't fit it in yet as I'll need to mod the carpet a bit and also wanna wire in the plug first, its pretty good though sits just lower than the brake pedal and when fully pressed the stop underneith just barely touches the plate. the bracket itself slots in between the raised bit where the wheel arch starts and the other black piece of metal on the bulkhead which I forget what its for, possibly part of the pedal box

and heres a couple of the engine as it stands now, need to mod one of the pipes running to the intercooler so it runs down the other side, and also need to fit the rear engine bracket and gearbox once I get the tool needed for the clutch.
 I snapped one of the rear bracket bolts in the block trying to fit it earler today so need to get that out first before refitting it