The Mk1 ABF Project

[cartertronic]

I'm about to purchase all service/replacement parts for the engine conversion, I figure it'll be cheaper to get them sent over with the engine than bother later.

Thought I'd record it here to be thorough.
To be ordered from http://www.car-partsonline.com/MyPar...nd=ChooseModel EDIT - Company has gone bust due to factory fire
The list I have so far is:
-Timing Belt Kit (including tensioner) website (same company as above URL) says £19.00!?
-Replacement Waterpump £17.95
-Altenator / AC belt ?
-Mk2 8v GTI 210mm OE Spec Clutch Kit £55.95
-Ignition Lead Set £38.95
-4 x NGK Spark Plugs £3.30
-Fuel Filter £6.95
-VAG Oil Filter £2.80
-Inlet Manifold Gasket (upper and lower) £3.21 + £2.85
-Exhaust Manifold Gasket £4.70
-Sump Drain Plug & Seal £1.05 + £0.31

Never serviced a Mk3 engine so let me know if there is anything else I should be replacing..

[Jarred]

are you just going to go for a standard clutch or something slightly uprated?

[h100vw]

A 16 Valve cover would be a better bet than a standard 8v one. Bear in mind the 8 Valve made 112Hp in it's toughest form. The ABF is 150Hp.

Gavin

[cartertronic]

Thanks lads, I confess to having a limited knowledge of clutch requirements etc. As the 210mm flywheel I have is from a 8v mk2 I figured clutch would be to suit, stands to reason they are interchangable at the same size..

So I take it there is a 210mm 16v clutch that would suit? Or will any other 16v clutch still be insufficient (as other 16v's had lower bhp)?

Is there a smarter after market alternative?

[Peter Jones]

If you're going to run the 020 box you need an 8v friction plate as the splines in the 16v boxes (Generally) are bigger.

What you can run though is the 16v pressure plate as Gavin suggests.

Plenty of options out there mine's a stage 3 unit from Spec in the US.

http://www.specclutch.com/products

[Peter Jones]

OK to be a little more specific now that I'm not rushing out the door to work.

The 020 boxes had two different input shaft diameters, most are the smaller type. This affects your choice of friction plate. You can get 210mm friction plates with either diameter spline.

Now, you'll find that a lot of listings for clutch bits don't make that terribly clear. What they do is list 16v or 8v types hence my generalisation above.

If a driven disk is list as 8v it should have the smaller and more common spline (input shaft) diameter.

If a friction disc is listed as 16v it should be to suit the larger diameter shaft.

Easiest way to find out what yours has is to look a gearbox chart like this one. http://www.techtonicstuning.com/trannyratios.asp

Best way to find out is to pull it out of the car and take a look.

Sounds like you've got a 4T box to play with which I think has the small i/p shaft.

To add some further complication there are two types of 210mm flywheel, single or dual pin. Either will work happily but it may affect your choice of pressure plate if it's specificc to either type. Most pressure plates are universal these days, especially the performance ones.

In summary 210mm flywheel, 8v disc, 16v pressure plate.

I've got exactly this setup in my car, you can read all about it the wreck to race thread.(link below)

Pete

[Golf Loon]

4T box has great ratios for what you want from it.

It also has the small input shaft.

So Pete Jones is correct with the kit you want.

GAP list one for that application which I have in the 20VT Scirocco and it has never slipped. Should be sweet attached to a 16v.

[cartertronic]

Thanks for the info!
I've done a little reading as I don't really have any experience in clutch mechanics and I'm pretty keen to understand this properly
Looking forward to getting home and checking my Haynes book to understand how everything attaches together.
P.S Pete, I had a look at your thread (loved the track vid )

Quick question, bit confused by your first post:

If you're going to run the 020 box you need an 8v pressure plate as the splines in the 16v boxes (Generally) are bigger.

What you can run though is the 16v pressure plate as Gavin suggests.

Did you mean I can't run a 16v friction plate as it won't match the spline on the 020 gearbox?

I didn't think the pressure plate had a splined hub (not sure if that's the right term) to fit the splined shaft, so I'm hoping that was a typo..

4T box has great ratios for what you want from it.

It also has the small input shaft.

So Pete Jones is correct with the kit you want.

GAP list one for that application which I have in the 20VT Scirocco and it has never slipped. Should be sweet attached to a 16v.

Thanks for that spline sizing Matt, saves me taking the box out to check

Based on this I'll need:
-the 210mm flywheel I currently have (hopefully it matches the pressure plate)
-a 210mm friction plate with fits the spline on the 020 box and has enough 'grip' to work with 150bhp.
-the existing 16v pressure plate on the ABF (or do I need to get an aftermarket one?)

[Peter Jones]

Did you mean I can't run a 16v friction plate as it won't match the spline on the 020 gearbox?

I didn't think the pressure plate had a splined hub (not sure if that's the right term) to fit the splined shaft, so I'm hoping that was a typo..

Yep, typo sorry. I was rushing to catch a train. I'll edit it just in case anyone is reading back for this answer later on.

That 16v Pressure plate you've already got should be fine. (Although I did blow up a stock one of those)

Pete

[Golf Loon]

You need a new pressure plate that comes with the clutch kit.

The one on your ABF is for a totally different clutch setup and gearbox 02a and so wont work. Get the whole kit from GAP and a Mk2 or Mk3 flywheel and you will be fine.

[jayjay]

i think i remember reading on a sachs site that the GAP HD clutch kit was from diesel mk2 taxis in europe.. good to know?

[cartertronic]

Thanks all, lucky I checked before making that other order

Just about to order the Heavy Duty 210mm 8v Clutch that comes with the 16v pressure plate from GAP ($125.60 US).


Although there is no way to tell price of postage without submitting order Anyone know how much postage is?

I know I have to replace the flywheel and pressure plate bolts, should I buy the clutch install kit ($55 US) with the other misc bits as well (rear crank seal, input shaft seal, push rod bushing and seal, release bearing and release bearing cover)?

[Golf Loon]

Yes that is the kit and yes buy the other kit and change all the bushings and seals.

Phone up and talk to a person and place the order. Get better service and prices than some annonymous random on the net.

[cartertronic]

Thanks for the help all, ordered and received the HD Clutch and Install Kit came to about $300AU.

After sealing up the car and completing the sound deadening project the heater core started leaking .. Murphy's Law is a killer!
Anyway, quickly got a new heater core, installed it and got back to dry golfing

Have been cleaning and refurbishing a set of Kelsey Hayes GTI brakes ready for the conversion. Only just finished stripping the paint and degreasing them, will post some pics once they've been resprayed with heat resistant paint and sealant.

I've ordered drilled and grooved discs and will be ordering new pads and braided lines in the next day or so. Ordering from the UK so all that stuff will be going in the crate with the engine.

Also looking at a rear strut brace, either

Mounts on top of strut


OR

Mounts on side of strut tower


Leaning toward the first one as it won't require drilling into the tower. Bit of a bargain at $45AU too!

[AUC-05L]

nice project.

is it expensive to freight and engine over from the UK? (if you dint mind me asking)

keep up the good work.