It Begins: The S3 1.8T into my '85 Mk2 GTI

[MattyT]

Let this cheer you up: http://www.youtube.com/watch?v=oavMtUWDBTM

[Golf Loon]

UPDATE:

I EFFING HATE POLYURETHANE CONTROL ARM BUSHES!!!!!!! STAB... STAB...STAAAB!

Wait till the car is running and the bushes are rattling every bit of trim in the car and your teeth. Then you will hate em even more.

[GOLFBALLS]

Making some good headway now.
pics coming soon.

I did forget something though.. I bolted up the flywheel/clutch assembly and forgot about that metal cover plate that goes between the block and the gearbox!

I've torqued up the flywheel stretch bolts and cant bear the thought of doing it again.

Does anyone know if those thin plates are REALLY an essential part? Will it be ok without it?

Cheers

[h100vw]

They stop road much getting in the bell housing. I'd fit it TBH.

I reckon I can help you out with the clutch cable. I got a couple of manual adjusting ones from the UK last year when I converted the Toledo back to a cable change box.

192 721 335C is the part number, it's for a 1300 MK2 Golf with manual gearbox. All the reading I did at the time pointed to it being the best way of getting rid of the auto adjusting cable.

Gavin

[peedman]

Hey wade do u still have any parts left over from the s3??

[GOLFBALLS]

Hey wade do u still have any parts left over from the s3??

A few bits and pieces. What you after?

[peedman]

A few bits and pieces. What you after?

Have u got a headlight switch or an armrest???

[GOLFBALLS]

Niether sorry.
Got stuff like dashboard, glovebox, wiper arms & motor (will fit golf 4), drivers side rear popout window, various door mechanism bits, etc.

[peedman]

ah darn thanks anyway tho. fyi the s3 has a different headlight switch to the a3's due to the xenons and self leveling. fact it is, whether its any use to u, prob not lol.

if i need anything from the dash ill let u know. i can swap u a mk2 manual adjust clutch cable if need be

[GOLFBALLS]

Ok, so it's update time and pics!!

Cleaned up the engine bay. It's not perfect, but this car aint gonna be no trailer bitch! It's gonna be a daily, and thats clean enough for me.


G60 mounts in (thanks Tim at Dubaddiction)


Getting out the old control arm bushes. Horrible.

[GOLFBALLS]

Cross member bushes out. Still trying to get the bastard poly ones in!!



Getting a bit creative putting in control arm poly bushes. More horrible!


After...


Old vs new G60 g'box mount


Same again for front eng mounts


And rear...

[GOLFBALLS]

02A Corrado/Ibiza Cupra/Passat/T4 gearbox brackets. (thanks loon)

Installed... Also note mechanical SEAT clutch lever


Gearshifter out ready for cable replacement


Mk2 p/s pump bolted up to 20vt bracket and mk4 pulley.


Machined 228mm flywheel, all torqued up WITH cover plate behind!!!


VR6 clutch together

[GOLFBALLS]

Thought while engine is out and i'm already broke, might as well do timing belt!

Old plastic vs new metal waterpump

Installed including belt, waterpump, tensioner and damper.


Still going strong after many late nights and confusion, but i'm on the home stretch now. My girlfriend hates this project!!
Engine will be in by the weekend then the plumbing begins!

[GoLfMan]

you sir are a champion

keep up the good work fella!

[Jarred]

Good Work! glad to see you're really getting stuck in!

Did you use a 16V tensioner for the timing belt??