So here we are on the new forum, I'll slowly migrate my build thread to here but as its 9 years long it could take a while. Not sure how complete it will end up being thanks to Photobucket.
Hey everyone.
Won't bore you with too much writing, so I'll make it quick and get to the pictures.
Passed my test last december. Couldn't find reasonable insurance on anything at the time, so I gave up and waited. Fast forward to march. Couple of my mates had insured Minis for a reasonable price with Footman James, So i decided I would try and find something abit different to the normal Clio or Fiesta. Rung them up and was happy to hear that although it was more than I wanted to spend, but I could afford it. So I found a 1.3 and got it.
It's an 86 with 91000(ish) miles. Bodywork is mint, only two bubbles of rust. It was resrayed to Tornado red by the previous owner. (twas the mucky red before i'm not sure of the name)
7 spline grill and BBS RZ ET33's.
It's been lowered, I'm not sure how far down (perhaps 40mm I thought?) It has lowering springs, not coilovers.
Also the other day I found out that it has 5 gears. I'm not sure if it's a 4+e gearbox or something else but it definitely makes motorways more bearable.
It needs a few things sorting out, mainly in the interior. The doorcards are from a newer golf with adjustable mirrors, the stereo doesnt work, and the seats wobble. But I'm hoping to get this sorted out within the next few weeks/months.
Not got anything planned after that I'm afraid. Being a student means money is tight as it is without modifications.
Enough talking here are some pictures,
(http://lp1.pinkbike.org/p4pb6637727/p4pb6637727.jpg)
And here are a few with me playing with my camera.
(http://lp1.pinkbike.org/p4pb6622230/p4pb6622230.jpg)
(http://lp1.pinkbike.org/p4pb6622226/p4pb6622226.jpg)
Anyway hope you like.
I shall skip over loads of boring posts of 17 year old me bodging things and generally talking rubbish. There are also no photos on any of these so i'll consign them to history.
Bascially, drove it for a year ish. In that time the head gasket went twice, I put it on coilovers, did a weber conversion, and swapped to a gti interior. I also managed to get one of the previous owners to send some pictures of when they painted it. oh how i wish this never happened :-X
(http://i284.photobucket.com/albums/ll11/notchnut/230947_1023419594811_1504873990_30101905_5044819_n.jpg)
(http://i284.photobucket.com/albums/ll11/notchnut/224067_1023419514809_1504873990_30101903_4123056_n.jpg)
(http://i284.photobucket.com/albums/ll11/notchnut/222372_1023419634812_1504873990_30101906_4880866_n.jpg)
(http://i284.photobucket.com/albums/ll11/notchnut/221702_1023419554810_1504873990_30101904_3922395_n.jpg)
(http://i284.photobucket.com/albums/ll11/notchnut/222697_1023419714814_1504873990_30101908_2885384_n.jpg)
(http://i284.photobucket.com/albums/ll11/notchnut/228002_1023419874818_1504873990_30101912_5467378_n.jpg)
(http://i284.photobucket.com/albums/ll11/notchnut/226767_1023419794816_1504873990_30101910_2665606_n.jpg)
After the head gasket went a 2nd time, with help of my parents I bought a reliable daily and the Golf went into storage while I was a poor student.
I decided that I would do an engine swap at some point but couldn't decide which engine. Initially I really wanted a tuned PD130 but as time went on I decided the sound of a VR6 would be hard to beat.
I started gathering parts, went wide track with MK3 subframe and rear beam, swapped the rear axle to a polo bearing setup, got ripped off on an engine, so had to buy another. Bought a V5 gearbox
All was going well until I dropped a bolt down a coolant passage whilst installing a SAI delete. This is where the pictures take off again so will continue from there....
(http://i.imgur.com/7h0Cyovl.jpg)
I haven't found the bolt, but i'm 80% sure its stayed in the head.
I did not see with my own eyes as I was working by touch.
(http://i.imgur.com/nZTUKLll.jpg)
The bolt went down the lower hole as I mistook it for one of the proper threaded holes around it. It didn't drop down immediately it sat on the ledge, then I managed to push it further in with my finger trying to get at it. Then Mr bright idea here thought I would just jam something behind it and scrape it out. This is when i'm not sure if it went in or came out. It sounded like the bolt fell a long way, hence assuming it fell into the block. I've searched the drive way and the subframe with 3 different people looking for the bolt just incase it did come out to no avail. It could have been washed away by now as the driveway is on a hill and we have had some very heavy rain recently. Perhaps it rolled from under the car and a Magpie has taken it, i'll clutch at any string right now :lol: :lol: :lol:
The passage is not straight, it has like a wall in it. I can get a pair of tweezers approx 7" into the passage and scrape it back to the opening, but alas no bolt appears.
(http://i.imgur.com/6mSpjU4l.jpg)
I'm at the point now where I either suck it up and run it, or I source a new head.
Feeling very down, but not quite out just yet.
(https://i.imgur.com/D4ulUiml.jpg)
So I bought an El cheapo borescope from ebay cause I wanted one last look through the head as I decided I was just gonna run it.
Look what I've found.... :roll:
(https://i.imgur.com/JxYZC4d.jpg)
I got it out. Once id found it, it was quite simple to remove.
So managed to get the engine mostly back together.
Cleaned up the block face and the pistons as best I could,
(https://i.imgur.com/m6SJjkol.jpg)
Headgasket on
(https://i.imgur.com/I6rj21Wl.jpg)
Headbolts worth a small fortune
(https://i.imgur.com/aUHHYlLl.jpg)
Renewed exhaust manifold bolts, old ones were mank and ceased.
(https://i.imgur.com/k7pZkXJl.jpg)
Still need to get a few o-rings and guide rails before I can button it up and get it back in the car. There's one guide rail I cannot find for love nor money. The part number is 022109513A. VW say its obsolete, but I'm not sure if it can still be gotten hold of in a full timing chain kit. If anyone knows where to get hold of one that would be great
(https://i.imgur.com/7Kb5HtSl.jpg)
Not much to report really. Engine is still in the garage. Thought I would share my latest purchase tho because it's absolutely beautiful.
(https://i.imgur.com/TTCPcK5.jpg)
Trackslag R32 Downpipe :D
Right.
I've finally managed to source a new slide rail from a guy who has started making his own over in Germany. They are great quality and if anyone needs one don't hesitate to contact me and I will pass his contacts details along for you.
So now that it has arrived I can finally get the engine back together and into the car!
(https://i.imgur.com/3lYGXC9l.jpg)
(https://i.imgur.com/A83Fy1ml.jpg)
It was at this time looking back, I really wish I had changed all the chains in the engine, but money was tight and I had decided that as the motor was so clean inside it probably wasn't needed.
Getting going again now.
Torqued up the cam chain sprocket and got the chain cover back on. Engine is mostly re assembled. A long time ago I decided I wanted a crackle red rocker cover. I attempted to paint it but it looks vile and chavvy and the paint didn't go down nice at all. So its off for powder coating next week in a nice OEM (ish) black.
(https://i.imgur.com/erm1fZHl.jpg)
Unfortunately there was a lot of pitting around the flange for the thermostat, luckily I had some JB weld at hand so have filled it in and I'll sand it down when it's dry.
(https://i.imgur.com/Y3WxJXTl.jpg)
Been rather busy over the past few weeks.
Engine went in on a very murky wet Saturday. Went in fine, apart from trapping a driveshaft in the wrong place so we had a little game of the hokey cokey.
(https://i.imgur.com/mRWpR8Hl.jpg)
Had a bit of a faf working out what to do about the oil pressure switches. A MK4 engine uses only one switch where as the MK2 clocks need 2. Luckily the oil filter housing on my engine has a blank to allow me to run both MK2 sensors. It seems like there is very little information on this on the net, but luckily it seems there are a lot of similarities between the 24V VR6's and the 1.8t in terms of how they work. Did a little bit of soldering as I had to replace the MK4 with just a plane spade. The photo below shows the pressure switch and at the oily alan key bolt can be removed and the other pressure switch located in its place.
(https://i.imgur.com/7AwTnn6l.jpg)
After all that, I decided to have a go at plugging everything into the fuse box to see if i'd get any lights on the dash. I was rather pleased when it all turned good.
(https://i.imgur.com/CrZzh1xl.jpg)
(https://i.imgur.com/EXdOKWhl.jpg)
All seems good so far, the engine turns over on the starter with the small amount of juice the battery has in it, but obviously wont fire yet as there's no fuel tank or pump in there yet. Only issue i've found so far is the dash lights don't appear to be working. :thinking:
(https://i.imgur.com/1zJfEmYl.jpg)
New intake gasket and cleaned out the throttle body ready for the weekend. A spot of welding is on the cards too.
Been busy over the past few weeks.
I quickly made some brackets to spread the pressure of holding the Polo shifter box in.
(https://i.imgur.com/L27YLudl.jpg)
I grabbed a few of my friends and we had a go at patching the inner arch just behind the fuel filler hole and also sorted the fuel tank mount out. Coated the joins in seam sealer and then a coat of epoxy mastic. Its not pretty and not the best we could do but it will do for the moment.
(https://i.imgur.com/yAMzYmQl.jpg)
Took a chance on some cheap silicone hoses from China. The brand got OK reviews so I went for it, still need to figure out what extra bits I need.
(https://i.imgur.com/tHmrJiJl.jpg)
Got the LEDS in the dash working, turns out id just been really unlucky and put every single one of them in the wrong way round.
(https://i.imgur.com/uW3RdKEl.jpg)
Trackslag downpipe went on.
(https://i.imgur.com/O2SnTZvl.jpg)
Swore at the fuel tank trying to put it on whilst rolling around in the snow.
(https://i.imgur.com/888cVpTl.jpg)
Then yesterday I was brave. Went and got a tenners worth of fuel, l soldered the wires for the MK3 tank and went for it. After quite a bit of cranking there was smoke coming out of the starter. I'd about given up for the day when I noticed a wire had come loose from the fuse box. Plugged it in, the fuel pump and throttle body came to life. Bit more cranking and it finally started catching and eventually spluttered into life. At which point the fuel filter started leaking but that's a job for another day.
https://www.youtube.com/watch?v=EWgU0utrb_0 (https://www.youtube.com/watch?v=EWgU0utrb_0)
Next thing will be cooling system and brakes.
Made some good progress recently. Tidied up a lot of wiring got the OBD port wired in and also got the rev convertor working.
I've decided I need to redo some brake lines as I'm not happy with the shaping of them.
Currently though I'm going out of my mind trying to figure out what coolant lines I need to get. Everybody seems to say just use Golf VR6 lines but the Golf VR6 lines I do have don't really fit, but I dont know if that's just because I got Chinese copies or I bought the wrong ones. It's so frustrating. I dont want to drop more money on things that dont fit when I have more important things like an exhaust and suspension to buy. :frustration:
(https://i.imgur.com/rS4W0lEl.jpg)
Oh and to top it off the sump is leaking.
Quick update, not many photos but plenty of writing.
Put a hockey puck under the front engine mount to try and pull the sump away from the subframe. However one puck is too much as now the bonnet hits the inlet manifold. :roll:
Went crazy with heat blanket, as now I'm paranoid about things catching fire after reading about a local lads MK1 cabby going up in smoke. Wrapped up the steering boot and also the gear cables. Bit messy but id rather me safe than sorry.
(https://i.imgur.com/QWZt3r3l.jpg)
Plumbed in the cooling system. It's a crazy concoction of pipes from 4 different cars but it appears to work. Plumbed in the power steering system too. Coolant is leaking from 2 places, power steering is not leaking but is whining pretty bad.
(https://i.imgur.com/YVV72Wvl.jpg)
I let the engine get as hot as I dared. (About half on the gauge) I don't have the fans wired in yet.
Seems to be idling weirdly high at the moment. Also desperate to buy the rest of the exhaust. Need to remake a few brake pipes before it moves on its own.
So got. A few bits done.
(https://i.imgur.com/P8TWoKQl.jpg)
I'm thinking of having a redesign of the intake system as I don't think there's enough pipe between the MAF and the air filter to allow the air to smooth out before it hits the MAF.
I've bled the brakes twice and they are still spongy. Clutch is spot on however.
But it did move under its own steam, albeit very loudly (it only has a downpipe on) and all the neighbours gave me dead eye.
(https://i.imgur.com/f2Qjekyl.jpg)
Made a loom with relay from the slimline fans it's nothing fancy but seems to get the job done for the moment just single speed to keep everything simple.
(https://i.imgur.com/TntPjhSl.jpg)
My biggest frustration at the moment is that I seem to have an issue with the engine. Firstly it idles pretty high, around 1050rpm according to vcds. It doesn't matter if it's hot or cold that's what it will do. Also when I rev it it seems to hang onto them, and take ages to get back to tickover. I've been going over the vacuum system looking for leaks but I haven't found anything yet. I wondered if I might have been a bit too forceful when cleaning the throttle body before I put it on . It's confusing, everything I read says that the idle should be erratic if it's a vac leak but mine is smooth, just a bit high. :thinking:
So this part was when rubjonny suggested wiring in a clutch and brake switch to try and sort my idling issues...
Haven't received a reply from the loom guy yet but I appear to have the wires present on the ECU end.
White and red on pin 39
(https://i.imgur.com/xOboWQAl.png)
Yellow and white on pin 55
(https://i.imgur.com/gQh7gTil.png)
I guess this is right? I've never had to find pins on an ECU plug :lol: I didn't see red/black on pin 56.
So it's as simple as following this now I've found them?
Clutch switch:
blue/black - ignition live
red/white - to ecu
Brake switch:
red/brown - original brake switch red/yellow
black/red - original brake switch black/red
blue/black - ignition live
yellow/white - to ecu
Apart from I could just ground the brake switch yellow and white wire instead of running wires to the brake switch?
So I finally managed do the wiring that rubjonny suggested and it partially fixed my problems. The engine no longer holds onto its revs when you rev it, But it's still idling just a tad high. I'm thinking it might be because it hasn't had various things mapped out yet, but I guess I'll just have to live with it for the moment.
(https://i.imgur.com/AYvm1OMl.jpg)
Incidentally filling the ears out on the pedal box was a pig of a job :confused:
Sunday was Trackslag day! Went for 2.5" offset single tip with the performance backbox.
Fits perfect and sounds awesome.
(https://i.imgur.com/J1fnIijl.jpg)
https://youtu.be/JV3gZIvZ_wk (https://youtu.be/JV3gZIvZ_wk)
Car is a bit smoky until fully warm though :thinking:
Things are still ticking over with this when I can. The daily has needed quite a bit of attention over the past few months so things have slowed here.
I've mostly hit snags that I don't know how to fix. For example, I bled the brake system, they work but not very good and even after putting a litre of fluid through them they are still spongy. The revs seem to jump up if keep pressing the brake pedal. (which I don't know if it's good or not)
Aand it's still idling at 1040rpm. No more. No less.
Thinking lambdas.
(https://i.imgur.com/NY8wb1gl.jpg)
Right there's a lot of pictures to add here. Ill try and keep them chronological.
Firstly chopped the top off the 02J shifter tower so I could tap the shaft for a MK2 style gear knob. A job i'm not rushing to do again. I really wanted to run the same one as I had in the 1.3 Its not particularly pretty but is sentimental.
(https://i.imgur.com/d28r8lYl.jpg)
(https://i.imgur.com/U4XNZNJl.jpg)
My AP's turned up. I got them out of the box and stared at them for a little while, they are stunning.
(https://i.imgur.com/ws7z6kSl.jpg)
I built them up on to MK3 topmounts which was a little challenge getting everything in the correct order. Went with Lemforder items cause people seem to say they are good quality.
(https://i.imgur.com/QbmTQWZl.jpg)
The MK2 mounts were well and truley shot. One of them fell apart as I took the old strut out :lol:
(https://i.imgur.com/A3EjkrAl.jpg?1)
New Lambdas to try and sort this high idle out. It didn't, but it does run much smoother, isn't over fuelling so needed them really.
(https://i.imgur.com/2n4Kz1Jl.jpg)
Popped those little battery adaptors on to stop it sliding about. Some may notice the part number, yes its a MK6 battery, but hey it was free.
(https://i.imgur.com/UwMtkXvl.jpg)
Got a few rust spots that need welding. I have borrowed my mates welder and im gonna do it. The issue is i've never welded in my life, so will see what happens.
(https://i.imgur.com/tDV3DX8l.jpg)
(https://i.imgur.com/ALm8gz6l.jpg)
Ended up finishing Sunday trying to put as much of the dash back in. Ignore the horrific fighter jet switch, I was a different person back when i thought that was a good idea. :lol:
(https://i.imgur.com/xBziF8Zl.jpg)
I did some other boring stuff that I didn't take pictures of, fuel filter and remade the Brake servo vacuum pipe out of nylon pipe.
So at the moment i'm getting closer and closer to getting the big red turd back on the road. Sending the V5 back to the DVLA to update the cars details and my to do list is slowly getting smaller. I'll get there one day.
Bonus picture of the daily which seems to eat parking sensors for some reason. :roll: :lol: :cool:
(https://i.imgur.com/xCf5HVJl.jpg)
8 bloody years I've had this car. 8 years I've thought there was a wiring issue with the rear fog light. Ive bought 3 fog light switches, thinking it was the switch but it didn't fix it. Every year for the MOT id take a feed from the fusebox and bodge a temporary fix to get me through... Until now when I decided I would conquer it for once and all.
(http://i.imgur.com/dfXzxQgl.jpg)
Being a pov spec Golf, I should have had a jumper wire in relay 7 on the fusebox. But some wise soul in the past had removed the jumper from the fuse box. £7 later and a number 53 relay bish bash bosh. The first time I've ever seen the switch light up.
Still on with this.
Done lots of little bits over the past couple of months. I've remade a rear brake pipe. Fitted 4 Rainsport 3s, refitted the arch liners, put the dash completely back together. All sorts.
Unfortunately the car is already breaking itself and it's not officially got off the drive yet. Last week the starter went. I've replaced that tonight and now its running funny, doing weird idling and running rich. Like it did basically before I replaced the MAF and Lambdas. Hope it's not those cause I can't be bothered to pay out again.
So heres a pic dump of random stuff.
(https://i.imgur.com/cBX8pd2l.jpg)
(https://i.imgur.com/XuzP7pUl.jpg)
(https://i.imgur.com/eC2cW5Sl.jpg)
(https://i.imgur.com/690BUHe.jpg)
Had a spot of corrosion right at the front of my sills. Luckily it appears I've just caught it in time. I used Deox gel to get into the nooks and crannies. It took probably 6 applications to get it all out but sorted it and now its coated in a nice think layer of epoxy mastic
BOOM :cool:
(https://i.imgur.com/hChtQTw.jpg)
No advisories either. Waiting for the DVLA to mess around with my V5, get insured and then i'm good to go.
(https://i.imgur.com/NirG6lpl.jpg)
Finally! The Golf has been on the road since Thursday, done around 100 miles so far. The thing is an animal and the sound it makes is insane! Had a coolant leak but checked the hoses and all the clamps needed tightening. Revs are hanging quite a bit which is annoying as it makes it difficult to change gear. Overall absolutely chuffed tho. :D :cool:
Up to 500 miles with the new engine. Been doing bits and bobs but nothing crazy interesting.
(https://i.imgur.com/D7gqsjdl.jpg)
Today swapped over my old battered sump to a new R32 one, this also meant swapping the oil pump. Here are a few pics from the swap.
Before with the patched up sump
(https://i.imgur.com/CspZOgml.jpg)
Sump and oil pump off
(https://i.imgur.com/F5t99iBl.jpg)
Side by side of the oil pumps. You can see the pickup is longer on one than the other.
(https://i.imgur.com/qjNwjDil.jpg)
(https://i.imgur.com/R4osm6Pl.jpg)
4motion pan left, R32 Pan Right.
(https://i.imgur.com/QZH5fskl.jpg)
R32 sump is baffled inside
(https://i.imgur.com/7NZpa6Ul.jpg)
End result, pan sits about level with the subframe, no need to worry about speed bumps.
(https://i.imgur.com/ciXC47Fl.jpg)
Golf was also on DIY duty this morning for a friend, I don't think we could draw anymore attention to ourselves if we tried! :roll:
(https://i.imgur.com/fOszwS4l.jpg)
Ordered a new radio and that will be the next job when I have a weekend free. Starting fresh so will be running new wires all round.
Currently got 2 massive issues that are doing my head in and i'm struggling with.
1st.
Its still idling high. It doesn't hunt, but where it idles does vary. I think this also ties in with problems i'm having with the revs hanging after you come of the throttle. Changing gears is a nightmare. One thing i've noticed is that when the car is cold, this problem doesnt seem to occur.
So far i've tried:
Tried 3 different MAFs
Replaced the MAF plug
New Lambdas
Spaced MAF further from airfilter
Isolated brake servo from intake
Checked the vac pipes more times than I count.
New coolant temp sensor
Wired in a clutch switch
Ultimately i've come to realise that the ECU is probably upset that its no longer in a MK4 Golf and needs mapping. I think ill probably send it off to Stealth for them to work their magic because i'm fed up of it now.
2nd
I've got a knock. It seems to come from under my feet and happens when i'm turning braking or when I come off the throttle. Another one I cant find. I've torqued every bolt I can see and its still happening. The only thing left to change is a ARB clamp that I have stripped the thread on.
Still having problems with the revs hanging and it idling high, so i revisited the clutch and brake switch wiring.
any codes logged in vagcom? also have you checked clutch and brake switch in ecu measuring blocks?
Here are my fault codes. Nothing jumps out at me here
9 Faults Found:
18057 - Powertrain Data Bus
P1649 - 35-00 - Missing Message from ABS Controller
18058 - Powertrain Data Bus
P1650 - 35-00 - Missing Message from Instrument Cluster
17834 - EVAP Purge Valve (N80)
P1426 - 35-00 - Open Circuit
17841 - Secondary Air Pump Relay (J299)
P1433 - 35-00 - Open Circuit
17840 - Secondary Air Injection Solenoid Valve (N112)
P1432 - 35-00 - Open Circuit
17530 - Oxygen (Lambda) Sensor Heating; B2 S2
P1122 - 35-00 - Open Circuit
17526 - Oxygen (Lambda) Sensor Heating; B1 S2
P1118 - 35-00 - Open Circuit
17606 - Oxygen (Lambda) Sensor Heater Circuit: B1 S2
P1198 - 35-00 - Electrical Malfunction
17607 - Oxygen (Lambda) Sensor Heater Circuit: B2 S2
P1199 - 35-00 - Electrical Malfunction
For the clutch switch
In "group 66" field 2 I have 1101
(https://i.imgur.com/tGfvdtel.jpg)
So currently the car thinks;
1 = CCS active in ECM
1 = Clutch Depressed (always 0 in Auto. Trans.)
0 = Brake Not Depressed(brake pedal switch)
1 = Brake depressed (brake light switch)
So, the car thinks the clutch pedal is down. Not sure about brake pedal currently?
After this I tested the clutch switch, its fubared. The numbers dont change when the plunger is pressed. The number does change however when you unplug it and it goes to a 0, so at least the wiring to the ECU is correct. I tested the switch with the multi-meter too, it looks like its got stuck "on" as the multi-meter showed continuity.
So after all this i've gone back through this thread and realised i've misunderstood what rubjonny said about the brake and clutch switch. I didn't realise I needed both! I'm still currently using the MK2 brake switch so ive ordered a MK4 one and will wire it in, along with getting a new clutch switch. Hopefully after all this my woes will be solved :thumbs: If not, im setting it on fire. :evil: :lol:
Just a quick pic dump here.
I put a new ARB clamp on at the weekend to try and sort the bang out but its still doing it. Have a feeling its the rear bolt that goes through the wishbone. I don't actually think the captive nut has broken free because I can still torque it up, but when i came to undo it, it came out super easy which makes me wonder if the bolt had bottomed out. The very end of the bolt had witness marks on it too. When I looked at the parts diagrams the MK3 item is longer than the MK2 one by 5mm. Which makes me wonder if I ordered the MK3 one and the bolt is bottoming out not allowing the sub frame to be fully tight. Ordered MK2 ones so will see what happens.
Had a quick look at wiring for cruise control.
(https://i.imgur.com/jOXImGWl.png)
(https://i.imgur.com/HWI1jtyl.png)
(https://i.imgur.com/X5hRTkMl.jpg)
All seems hunky dory however there should be a pin and wire in no 56 however there is nothing. There also should be pins in all of the ports regardless so it would appear someone has been here before. :confused:
So here's where we were before.
Heres the old bolt and the new one from VW Heritage. You can see the witness marks on the end of the old bolt. I swapped it and it seems to have got rid of my braking thud but I still have a little clunk when turning. I still need to replace the passenger side bolt. I ordered 2 and only 1 appeared. Typical!
(https://i.imgur.com/ZQr5ookl.jpg)
(https://i.imgur.com/t8ICAK8l.jpg)
Finally got a radio in. Its nothing special, but does have bluetooth! I re-did all the wiring for this so at last its nice and tidy. As a common theme for this car, the dash has been hacked to pieces in the past, presumably to get a previous radio in. That means that the support is missing from the back and as a result my new one flaps about on bumpy roads :roll:
(https://i.imgur.com/VElAoI8l.jpg)
While the weather was bad and i'd managed to wangle a spot in the garage I took a look at a patch of rust on the back passenger corner. I didn't think it was that bad, but the occasional weekend drive out over the winter seems to have took its toll. I buzzed it with the wire wheel. B******s, it went through! Decided to give it a coat of Hydrate 80 and then managed to fill the hole with chemical metal. Janky I know, but this isn't intended to be a permanent fix. Few coats of primer and a bit of Halfords finest Tornado Red and it'll do for now.
(https://i.imgur.com/ZeBoTzTl.jpg)
(https://i.imgur.com/ASEAlHbl.jpg)
Doesn't look so bad from 5 foot.
(https://i.imgur.com/AXtBSxHl.jpg)
Finally managed to get rid of the plastic intake tube which made the air filter sit at a daft angle, and had an alloy pipe made up. I took the opportunity to get a massive ridiculous air filter. I’ll paint the pipe black eventually. The engine cover rubs with the bonnet down, which is a shame as it hides a lot of tat.
(https://i.imgur.com/3cGZKLwl.jpg)
Finally today I got around to fitting the cruise control. I went through 4!!!! Clutch switches before I managed to fit one without breaking it. It is imperative that the ears you file out of the pedal box to fit the MK4 switch are straight. The brake switch flew in without any issues. Working methodically I added one wire at a time to the ecu plug, testing with VCDS to confirm everything was hunky dory. Fitting it was uneventful and it worked first time.
(https://i.imgur.com/iFXhEkFl.jpg)
That’s as far as I am at the moment. The engine is still playing up, the clutch switch has fixed the revs hanging issue when changing gear but it’s still idling high. Something that seems to have started happening since I sorted is say I pull up to a junction the idle revs are high and slowly start to increase. I’ve noticed if I put the clutch pedal down the revs drop and seem to settle around 960rpm. Sometimes it will stay about there and then other times it will slowly creep back up. Sometimes to 1200rpm, sometimes higher. I need to drive it a bit more and try and figure out a pattern as to when this is happening.
I’d like to sort the chains out soon. I’m trying to figure out whether I need to do them before the national meet or if I can wait till next winter. They are a little noisy until the engine is warm but once up to temp they are barely audible. At the moment I’ll take it as it comes and keep an ear to the engine bay. I’m hoping I’ll be able to maybe install a longer 5th gear and an LSD when everything is out.
I’m also planning to do a coolant flush and put on a new header tank, install fog lights/driving lights and also redo all the membranes in the doors because every time it rains I have to remember my wellies when I go for a drive.
Quick little update from me, I've been furloughed for the past 6 weeks so I've had plenty of time to get stuff done. So, starting from the beginning;
The coolant I had in it was really just a temporary measure to tide me over winter so first thing was to do a proper coolant flush and then refill with proper G13. I ordered a nice clean new coolant bottle while I was at it and ordered 2 lots of G13 to mix with water. I didn't pay attention and bought premixed G13, so it came and I didn't have enough. Stupid mistake...
The paintwork on the Golf was shocking from being under a cover for the past 8 years, so I thought it was about time to grab a machine polisher and try and get it looking more respectable. in some areas its come up pretty well and I am happy with the results I got. It appears that when the car was painted it didn't get a clear coat, and as you'd expect from a drive way the quality is shocking in some places, with runs, fish eyes and orange peel all over the place. The rear valance, grill strip and front valance appear to have had absolutely no preparation before they were painted which means the paint is simply flaking off. Anyway here's the result of polishing the bonnet.
(https://i.imgur.com/eU0XC8rl.jpg)
Next up was chasing that stupid issue I was having with it not idling right and and the revs hanging. As of my last post I had changed all sorts of stuff to try and find it. My last attempt before I sent it off to someone for sorting was to swap the MAF again and also to take the Manifold off and check for vac leaks. At this point I was clutching at straws and had so far changed;
3rd MAF so far. 1st came with the engine, 2nd was 2nd hand, 3rd was brand new.
Changed lambda sensors
Brand new Febi coolant temp sensor and then a new OEM coolant temp sensor.
Fully wired in a brake and clutch switch as it would work in a MK4
Checked over the entire vacuum system more times than I’ve had hot dinners.
Tried a different throttle body
New genuine fuel pressure regulator
(https://i.imgur.com/0cTvL2Tl.jpg)
Took the manifold off, made sure the gasket was seated properly but it back together. Absolutely no change what so ever. Pulling my hair out at this point. It was behaving like a vac leak, but there was no vac leak!
Decided to break out VCDS and try and figure out from the MAF values if I could see anything amiss. With my limited knowledge, it all seemed fine, however I noticed that when I rev'd the engine the % load didn't always fall to the number it was before I had pressed the throttle. Although the pedal had completely come back up, I pulled the pedal back up with my foot and to my amazement the revs dropped, right down to 900rpm and stayed there. Rev'd the car they went up slowly came down, and then settled on 1200rpm. Pull pedal back up, drop to 900rpm. Ordered a new pedal for £13 plugged it in and its working perfect. The car is actually nice to drive now, semi annoyed I spent all that money on the other things and it took me since last October to figure out, but fixing this has increased my confidence in the cars reliability 10 fold.
(https://i.imgur.com/efPCUYyl.jpg)
Finally. Saw a small bumper with fog lights, wanted fog lights, fitted fog lights. They aren't wired in yet, but I think will do it so they are high beam lights rather than fogs. More useful that way.
I always start these posts with an aim to keep the writing short but somehow I end up writing a novel every-time. I apologise if this is boring. If I managed to keep you to the end, thank you for reading.
I've gone and completely neglected this thread. Mainly because I've been driving and enjoying the thing. Lets have an updated.
First thing engine cover and battery cover, the one specific to this engine. I think it looks tons better. I'm not chasing a super clean perfect bay but I want it to look nice and tidy.
(https://i.imgur.com/rKVs6lg.jpg)
Alternator died. Thankfully it went on the blink intermittently so didn't get stuck anywhere. Engine conversions are great and all but when the entire front end has to come off to get to it it becomes annoying rather quickly.
(https://i.imgur.com/FBPfteA.jpg)
Found quite a leak
(https://i.imgur.com/RmYnOZz.jpg)
(https://i.imgur.com/GDwuuSy.jpg)
That was pretty much it, rest of the year was smooth sailing. tried a couple of different setups on the front. Personal fave is the first one. I put some 20mm spacers on the back and it looks mega. Unfortunatley I need a bit of work doing on the arches as at the moment it rubs just a bit too much. I did try rolling them myself but the one I tried crumbled. Decided to give it up as a bad job, will hand it to a pro at some point.
(https://i.imgur.com/GiOTAMw.jpg)
(https://i.imgur.com/i9MYS9Ql.jpg)
Finally fitted proper door membranes with some sheeting. Buytl tape is the way forward here!
(https://i.imgur.com/Ub11oll.jpg
Couple of trips to the Motorist Hub at Sherburn. Great place, just what the North needed. I added a Heckblende, it just a Heko one so will probably be faded soon.
[img]https://i.imgur.com/2FSsmGJl.jpg)
Cant go wrong with a bit of sound proofing
(https://i.imgur.com/WGk8pNWl.jpg)
That pretty much brings me up to date. I sorned it at the end of November as I have plenty planned to replace/upgrade this winter.
So firstly, the upgrades. They mostly focus on brakes and handling. Never really been happy with the brake and although I can lock up the wheels if I stab at the pedal, I seem to have to press hard for them to actually do anything. Hoping good pads and disks along with a fluid flush should set me right. Gone with Tarox Strada pads. Have them on my daily and they are brill. Disks are Mtec C hooks. I only got them cause they look pretty and are coated... hahaha
(https://i.imgur.com/Bb5Feso.jpg)
(https://i.imgur.com/m7dvZRo.jpg)
Handling wise so far, I have a rear upper strut brace and a Eibach Rear anti roll bar.
Strut brace is from a company on eBay from Poland called Staffa
(https://i.imgur.com/V7XEdpW.jpg)
(https://i.imgur.com/ciRmSEL.jpg)
I've been desperately trying to find a front strut brace but so far I have bought 3 and none of them fit. 2 of them ended up being for LHD and one fits the struts but appears to be for a MK3 as the bonnet wont shut when its installed. Given up for the moment.
Over Christmas I started stripping down the engine bay ready to take the engine out to replace the chains which have been a little noisy ever since conversion. It all went pretty smoothly apart from one drive shaft bolt where the spline had been rounded. Chopped the head off with the Dremel and all was well!
(https://i.imgur.com/SuqXBmil.jpg)
(https://i.imgur.com/mVcRyqLl.jpg)
It was an absolute nightmare to find a timing chain kit for this engine. I had to wait for Febi to actually start making them and even then it wasn't a full kit. Luckily I found that the missing chain uses the same part number as an chain in a S4 engine and managed to fit it separately.
(https://i.imgur.com/HPrtMKN.jpg)
I'll be fitting a longer 5th gear and tidying up the block and engine bay whilst the engine is out.
Right then, time for an update.
Almost as soon as the engine was out of the car I started ripping it apart. Removing the timing covers just confirmed what I already suspected. The lower timing chain tensioner was absolutely goosed.
(https://i.imgur.com/uB8AY1ol.jpg)
(https://i.imgur.com/xcMZhkFl.jpg)
Swapping the chains was much easier than I thought it was going to be with the cams locked off, old chains and sprockets marked up and marks transferred onto the new chains.
(https://i.imgur.com/PSNl2Agl.jpg)
With that done, I turned to cleaning up the block. Stripped it the best I could and hit it with some paint.
(https://i.imgur.com/u1JJItsl.jpg)
Turned my attention to the gearbox next. Swapping the 5th gear ratio out for a longer one. I'm currently running a EBS gearbox from a V5. It's very short, which means cruising on the motorway used a lot of fuel and was pretty loud
I've gone from 0.837 to 0.717.
Cruising at 70mph/112kmh is now 2950rpm, was 3450rpm.
Top speed is now 155mph/250kmh was
134mph/215kmh
(https://i.imgur.com/3L6neUul.jpg)
(https://i.imgur.com/vLaSrINl.jpg)
The guides on the internet made this look super easy and logically it was. The fact I had to stand on the bell housing with a breaker bar on my gear puller showed me it was not. Thankfully I got the gears off without breaking anything.
If anyone was wondering a AUE 2,8 with a V5 EBS 02J gearbox apparently weights 218kg
(https://i.imgur.com/5Ql6DJ2l.jpg)
And finally here's the whole thing ready to slot in. It all went pretty easy and it took me a few hours and it was running.
(https://i.imgur.com/2jSdFfnl.jpg)
(https://i.imgur.com/CoDQDtWl.jpg)
First drive was a bit of a disaster. 3rd gear didn't exist, and the water pump pulley came loose. Touch wood however all seems hunky dory now.
Not much to report, just been pootling about.
Popped to the Motorist Hub at Sherburn in Elmet for the first meet back. Its a nice venue for a Sunday morning coffee, buttie and chinwag. I'd highly recommend popping over if you're not a million miles away.
(https://i.imgur.com/aPFlsTpl.jpg)
Thanks to the grass for providing me with fake lows.
Then thankfully enough I managed to dodge rain showers and get some handling upgrades on the back end. Eibach Rear anti roll bar on the rear beam. Then also a BAF K-brace for the boot. Couple little pointers on the K-brace though. A full size spare wont fit in the wheel well anymore and the parcel shelf mounts need the brackets chopping down so the brace can sit on the strut mounts.
(https://i.imgur.com/LWOhYfxl.jpg)
(https://i.imgur.com/pBjf0Jll.jpg)
That's all for now. Plenty more planned for when I have a moment.
Great read, just about to start a similar project. ;D
Great read, just about to start a similar project. ;D
Thanks, I really should update this more often!
Good luck with your Project!
Quick update time!
Nothing massively interesting.
Scarbs on the hottest day of the year. It was so hot the sound deadening on the floor plan melted. Fortunately the Golf performed perfectly
(https://i.imgur.com/nOUFqxTl.jpg)
Highlight of the year how ever was RetroRides Gathering. Had to bring he paintwork up a little. Used the DA, with some medium cut Mezerna on a Orange Hexlogic pad.
(https://i.imgur.com/cWFIr9Z.jpg)
And finally I applied to go up the hill at RetroRides, Shelsey Walsh. Initially I wasn't picked. But a few days after hearing the news I got another email telling me a space had come up if I wanted it. I had never done anything remotely similar so was super nervous. But all I can say it was addictive and hopefully I can get on the hill again at next years event.
(https://i.imgur.com/mNJFX3kl.jpg)
(https://i.imgur.com/rwLvFeI.jpg)
2nd photo shows why I need to get a diff sorted out.....
Great little update.
Loving the one tyre fire you got going on there!
Small update!
Car has been in and out of the garage since October. Decided to finally get rid of the cabin leaks once and for all. Was leaking both coolant from the heater matrix and rainwater through either the rain tray or windscreen. Matrix looked ok, so must have been the pipes that join it to the rest of the coolant system. Whilst the matrix was out, I took the dash out to try and address the rainwater leak. Turns out it was coming in all along the bottom of the windscreen, and although there was no visible rust on the worst side, It was rather crusty on the seam.
(https://i.imgur.com/ITWX62Jl.jpg)
(https://i.imgur.com/SHAGGUzl.jpg)
New wheels incoming!
(https://i.imgur.com/dFn78Jql.jpg)
Quick update....
Got covid, thankfully not a bad case. Which gave me plenty of time to get to work.
(https://i.imgur.com/QvWUUCbl.jpg)
Proper chrome bumpers, Ronal R50 16x7.5 and rub strips stuck back on.
Unfortunately one of the wheels got knocked over just before fitting. My dad who did it was as gutted as me. Thankfully he's sorting it out.
(https://i.imgur.com/1k1WeEXl.jpg)
Searching through the shed I found some more sound deadening so continued sticking that in. I'd already done the boot so moving forward under the rear seats were next. Strategically placed 2mm silentcoat and some high density foam on top.
(https://i.imgur.com/cc1Bw0Fl.jpg)
Next up is probably more sound deadening, and underfelt before the carpet goes in.
(https://i.imgur.com/pkO5Wiyl.jpg)
(https://i.imgur.com/NSi9VLrl.jpg)
Currently got a poorly Golf, dodgy cam position sensor so it's been hicuping and randomly cutting out.
(https://i.imgur.com/Uz6qBu6l.jpg)
Replaced the camshaft position sensor. Fixed the hickups but it's still stalling at junctions :(
First time going to a national meet. Had a brilliant time!
(https://i.imgur.com/m9i9IdHl.jpg)
(https://i.imgur.com/pTVwr7Pl.jpg)
Car was running very hot on track, but performed brilliantly all day. Brakes had a run for their money after a brief stint as the Curborough ring taxi with me and 3 passengers.
Thank you to everybody who had some part in organising the weekend, also thanks to everyone who attended for being so friendly and welcoming
I didn't get chance to talk with you but recognised your car. It was going well on the track!
I didn't get chance to talk with you but recognised your car. It was going well on the track!
Thanks Ian! It was a lot of fun!
I didn't get chance to talk with you but recognised your car. It was going well on the track!
Just like Ian, you were so far off up the end, I never got a chance to say Hi.
Looked good when it was going about though!
Damn, I didn't recognise the car sorry, I hate it when I miss the opportunity to say hi.
It does make me wonder if we need some more ice-breaking activities organised, also I don't think the linear nature of the camping helps. The first year at Curborough we camped in the top field and I think that got people mingling better. Things to think about for next year.
First proper track day at Blyton last week with the lot from Frank's Charity Track Days.
(https://i.imgur.com/zOVcb8al.jpg)
(https://i.imgur.com/qFqvF0Yl.jpg)
(https://i.imgur.com/q5sA8W1l.jpg)
(https://i.imgur.com/OogeoE6l.jpg)
As you can see it was a tad damp. Couldnt get any real power down, and was spinning all the way into 4th. Had one off, overshot a corner and straight onto the concrete run off so no damage done.
It's still running like crap, I've had a lot of guesses on what it might be. Currently I think it's injectors as it runs better with no fuel pressure regulator.
love it on these wheels :))
love it on these wheels :))
Thank you pal! :) Dropped on so lucky with them!
New parts ahoy! Got suckered in by black Friday didn't I ::) O:)
(https://i.imgur.com/01yBhW3l.jpg)
(https://i.imgur.com/uV21uK5l.jpg)
Another track day in the bag. Swapped onto my old Rainsports at 10:30pm the night before as the forecast looked awful. Thankfully although damp, the weather held out.
(https://i.imgur.com/TCRTkZ7l.jpg)
(https://i.imgur.com/2XVgTc2l.jpg)
(https://i.imgur.com/Ba0g741l.jpg)
Stripped the Golf down to take the injectors out and send them off to R-tech to be refurbed. I mullered 2 out of 6 and borderline damaged 1. They were well stuck in. Ordered 5 from a V5 to replace the damaged ones. Apparently the flow wasn't very equal between them all so hoping they can work some magic on them! Looking forward to getting it back together already.
(https://i.imgur.com/UGyXCDpl.jpg)
(https://i.imgur.com/71r5e1al.jpg)
(https://i.imgur.com/nZoyDByl.jpg)
(https://i.imgur.com/ToXT4Nvl.jpg)
Mine were pretty cruddy especially around the air shroud ports, partly why I think they were so difficult to remove.
Really think I need a cool spoiler to finish the back of this off. Anyone got one for sale?
(https://i.imgur.com/D2Kuliel.jpg)
And this is why I can never have nice things. Because I'll probably damage them. :-X :'(
(https://i.imgur.com/Dxo0awwl.jpg)
(https://i.imgur.com/ylhf3fKl.jpg)
Bummer, but at least it's just the lip and not the painted body that protrudes.
If you look at the end of my post here (https://www.vwgolfmk2.co.uk/clubforum/index.php?topic=118.msg11780#msg11780) I fixed my wheel that was worse than that with a cheap DA I got from Amazon. So far I've only done one wheel as a trial and didn't got so far as to a finished polish. Your damage is minimal so you'd be able to sand that back and polish no trouble.
Can you get away with wider tyres?
Might stop it happening again in the future and give you a little more grip on the track.
Apologies for the slow reply, I really should check back here more often.
8864]
Bummer, but at least it's just the lip and not the painted body that protrudes.
If you look at the end of my post here (https://www.vwgolfmk2.co.uk/clubforum/index.php?topic=118.msg11780#msg11780) I fixed my wheel that was worse than that with a cheap DA I got from Amazon. So far I've only done one wheel as a trial and didn't got so far as to a finished polish. Your damage is minimal so you'd be able to sand that back and polish no trouble.
I took the wheel to the local tyre place and he told me exactly the same as you, have a go at sanding it slowly working down the grades. He could do it but would have to relaquer the whole wheel and couldn't guarantee it would stay the same colour. Absolutely astounded how well it has come out!
(https://i.imgur.com/Y2uPsQsl.jpg)
(https://i.imgur.com/kWTS19ml.jpg)
I think I could improve it further spending a bit more time with the DA but I'm at the point where I struggle to find where I've sanded it. Very relieved haha
Can you get away with wider tyres?
Might stop it happening again in the future and give you a little more grip on the track.
I could I'm sure if I got rid of the spacers on the back, but I'm super happy with how it sits at the moment. I'll just have to be much more careful around left hand bends O:) ;D
Great work, I’m yet to finish mine :D
Good save and you've learnt a new skill, win win!
I've managed to wallop the wheel again reversing into the garage. Still pretty sick about it tbh. Ordered some gold touch up paint in the hope I can get it looking semi decent.
Spent the rest of the weekend feeling sad and cleaning. Jetwashed all the arches out and all the underside. Got fed up of pink Matt paint so got the machine polisher out. Going to have a crack at Ceramic Coating it hopefully to stop the paint oxidising.
(https://i.imgur.com/S9R3FoVl.jpg)
(https://i.imgur.com/i2edkIGl.jpg)
Bummer about the rim. I bashed mine again the other day, easily done. But for me it was just a reminder to get on and fix them anyway.
Great result with the polishing, red really does come up well. I've been going over mine a bit at a time, you don't get the same kind of pop with white but the shine really does come out.
Bummer about the rim. I bashed mine again the other day, easily done. But for me it was just a reminder to get on and fix them anyway.
Great result with the polishing, red really does come up well. I've been going over mine a bit at a time, you don't get the same kind of pop with white but the shine really does come out.
I actually wished it had hit the chrome around the outside as I might have stood a chance at fixing that better. Hey ho! What it has told me is that I could never be one of the stancy people with wheels worth stupid money because I'd destroy them in no time ☠️
Thanks! I have a love hate relationship with detailing but it is worth is when you get results like this. I think little and often is the key to things like that!
Wanted some kind of spoiler for aaaages, as I always felt the back end was missing something. Managed to find a Hella double. Paid more than I wanted to but hey I think with that the exterior is finished.
(http://i.imgur.com/Sb7kb5G.jpg)
(https://i.imgur.com/Iwzc8rIl.jpg)
Friendly PSA that if you haven't checked your fuel lines recently, you probably should.
(https://i.imgur.com/Vt6e9nXl.jpg)
(https://i.imgur.com/JMDK2xAl.jpg)
I had a similar event recently, the outside had only just visible cracks when I squeezed it.
But on the inside it was starting to perish badly!
After the national meet I chucked it in the garage for a couple of weeks. I pulled it out of the garage to move it about and it had sprung a coolant leak coming out where the water pump meets the block.
Crap... I was booked in for mapping in 2 weeks. I didn't know if it was possible to swap the water pump on a VR6 without taking the engine out the chassis leg is right in the way. After a few words of advice I decided I was going to jack one side of the engine up and hopefully it will pivot on the gearbox mount.
(https://i.imgur.com/CT1pdf2l.jpg)
PSA the power steering hard line won't clear the cross member....
On to mapping day... I took the plunge and took it to Stealth. Vince put it on the roller and reckoned after the first pull that it had been mapped before. I never knew but it revs to 7k. First run it put out 229bhp.
(https://i.imgur.com/DPg0Hfql.jpg)
Ended up with 239bhp and more importantly the driveability is vastly improved and the engine is much happier.
Finally after all the days excitement we popped into Caffeine and Machine on the way home.
(https://i.imgur.com/dl6XEQxl.jpg)
That's a great result, don't they only come with 205 from the factory?
34bhp up on stock for a NA engine is really good going!
Yes mate that's right! It drives so much nicer. He's raised the idle speed a little too. Much much smoother.
Another day at Blyton in the bag.
My first dry track day highlighted an issue. My brakes last no longer than 15-20minutes before they get a bit warm and stop working ::) So need to figure something out with that.
(https://i.imgur.com/zQDGnxRl.jpg)
(https://i.imgur.com/UV2nyezl.jpg)
What brakes are you running?
What brakes are you running?
They are 288mm up front. Tarox Strada pads with m-tech c-hooks.
In the back 239mm solid disks and I have no idea what pads 🤣
Hmm, sensible brakes, when was the last time you changed the fluid?
I run the motul high temperature fluid, stops me boiling it on track.
A little trip to the Motorist a few weeks ago.
(https://i.imgur.com/TunAJull.jpg)
A little trip to the Motorist a few weeks ago.
(https://i.imgur.com/TunAJull.jpg)
Hi, great looking mk2 :) I have a question - what about current tyres size? Im interesting particular in width ofc, Greetings
Hi, great looking mk2 :) I have a question - what about current tyres size? Im interesting particular in width ofc, Greetings
Thank you ;D
The wheels are 7.5x16 ET38
Tyres are 195/45/16
Great national meet as always! Nice to see some familiar faces, unfortunately don't think I managed to catch up with everyone!
(https://i.imgur.com/nxoa6uDl.jpeg)
Golf did fine all day and got 19 laps in on the Saturday. The car really does get hot at curborough, but it didn't falter.
Already looking forward to next year!
It's always the way, I come away thinking I wish I'd had chance to catch up with more people. Car looked great.
And I was suffering from Hot Start issues, I had to pop my bonnet between runs too to help with cooling. Nice to actually have the weather though. Even if it did change a bit later on, lol.
It's always great to catch up mate!