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

[Jace]

Your wife/girlfriend knows what a turbo is? That's awesome!

[GOLFBALLS]

Hahahaha! Yea only cozI'm constantly boring the crap out of her with 'car talk'!!

[GOLFBALLS]

Grant came round and helped bleed the brakes so its drivable now.

Took it to work this morning (only 5 mins away) to get a quote for an exhaust system and map check and got to fang it once or twice. Acceleration is like being bashed in the guts with a medicine ball

Much fun and demerit points is upon us comrades

[MattyT]

To quote the girl in the vid: HOORAHHH!!!

It sounds a lot like my dads turbo diesel hilux, not bad for a 1.8t!

[geoff_gti]

Much fun and demerit points is upon us comrades

w00t w00t!!

[GOLFBALLS]

This morning I had a little time to check over a couple of things. The left rear tyre almost rubbed thru so i've raised the rear end up about 15mm and folded up the inner arches a bit. That seems to have stopped the rubbing! There was bloody tyre smoke coming from the arch as i was driving along before!!!

There are a few little problems to address though. Those supposed G60 heavy mounts from GSF are not firm enough. I should've known not to buy cheap crap from them. It's proof that you really can't cut costs with those sorts of things.
There's only so much I can shave off that master cyl and the timing belt cover is bumping against it when its loaded up under acceleration. It's even cracked the plastic although I checked the belt and there is no sign of rubbing... yet.

There's also something funny happening with the voltage to the left headlight as it's faint, and there's something loose in the drivers front strut top mount as it's knocking and rattling over little bumps.

Next week i'll get an exhaust on it and have them hook it up to a wide band A/F ratio meter for a mixture check, get a fan on the rad, and back up to golfwagen to sort the mounts and suspension rattle...

[GOLFBALLS]

Ok so final chapters approaching now. Its booked in at RPW on wednesday for the cat back (in mild steel for now) and to then hook up the wideband to make sure the fuel mixture is ok.

i'll put up some pics soon.

[DubSteve]

Great news wade, keep up that motivation mate

[Jarred]

excellent news!

Time for some videos!

[gareth_oau]

what on earth are you putting an exhaust on it for?

don't you (or the cops) like the 'tractor' sound? LOL

[GOLFBALLS]

Haha, the tractor sound has gone now that the oil has spread nicely thru the engine.

The next main jobs are monitoring that engine movement and keeping a close eye on the turbo temperature and water flow.

Then I'll mount the slim fan and change the thermostat to a 75 degree one. Joe also needs to fix up the drivers front strut top mount which is loose.

Cheers

[GOLFBALLS]

Hehehe. Just got a call from the exhaust shop. Reckons the back end was too low to fit a single 2.5 pipe near the rear beam. Awesome!

[gareth_oau]

so you're plumbing over the roof instead?

[GOLFBALLS]

so you're plumbing over the roof instead?

Nah man, drill thru the floor and into the boot and out the tail-light...

I did get a call from the tuner earlier. Says the exhaust sounds really nice, and isn't stupid loud.

Also, when he put it on the dyno he only got one fast run before the bottom rad hose blew off from the engine movement. Dang

...But, he did get a quick reading and as expected, it's running very lean. Still got the 3BAR RV fuel pump, so no surprises there. It was apparently reading around 150bhp - 160bhp between 2000rpm up to around 4000rpm, then suddenly the fuel mix richened up and whack it suddenly shot up to 218bhp, but was still a little lean.

Should get quite a bit more once it's getting enough fuel. I thought it felt very dull down low.
So, now to swap the fuel tank for a mk3 one and pop that 4 BAR VR6 fuel pump in there. That should sort things out.

Pics soon i swear...

[GOLFBALLS]

OK so time for a little update. Saturday morning I swapped in the mk3 fuel tank and got the brand new VDO VR6 pump in:




mk2 and mk3 tanks. spot the difference. The old mk2 fuel pump is tiny in comparison. Getting the plastic in tank fuel tubes off the float assembly is a ****ful job!



all strapped in:




Had to solder on the slightly lager 4-pin terminal for the later pump. (old mk2 plug on bottom)




...and all wired up ready to go



There's a bit of a leak from one of the overfill tubes but nothing i cant fix in a few minutes.

I just hope this fixes the lean running issue.

Cheers