'96 VR6 - Auto to Manual [Build]

[MilkIsYum]

Hello,

I've recently picked up a '96 Dragon Green, MK3 VR6 with 127,XXX KM's on the clock. (My first Golf!)

My car experience is limited, but I've been non stop lurking forums and finding out what I can, so I've taken the plunge and decided to do a full Automatic to Manual conversion!

The donor car has already been bought! (Proud owner of TWO golfs now, ha) A burgundy VR6 from another forum member who was parting it out! It has I think around 17X,XXX KM's on the clock? It's got most of the valuable parts stripped out, but still has the engine and gearbox (plus pedals, gear linkage etc. etc)


New Parts List:

Clutch- Received
Flywheel - Received
Clutch Master Cylinder - Received
Clutch Slave Cylinder - Received
Timing Chain Kit - Received- Current Job!
Heater Core - Installed
Oil Filter - Received
Air Filter - Installed
Front + Rear Wipers - Received
'Bee-sting' Arial - Installed
Rear Crankshaft Seal - Received
Front Crankshaft Seal - Received
Oil Pan Gasket - Received
Head Gasket - Received
Rear Brake Discs - Received
Rear Brake Pads - Received
Front Strut Mounts + Bearings - Installed
Alarm/Remote Locking System - Installed - (Struggling to wire 'total closure' to work with the remote!)
Clear Front Indicators - Received
Coil Overs - Received
2nd Hand Parts:

Black MK4 Leather Seats - Received - Need to weld on the MK3 rails
Thule Roof Rack w/ Fairing - Installed


The old roof liner has been removed and I need to put a new one in, going to try and use the foam from the donor car and get new material to cover it with.

I'm happy to take on any advice from anyone who has experience with any of these repairs I'll be doing. Having more information is always welcome! Likewise, happy to help where I can!

Pictures from when I picked her up:

[cliftronix]

Looks insanely clean. Is this the vr that had the 'engine rebuild' that was for sale?

[Juzzpc]

I feel like this is going to become a great thread


Sent from my iPhone using Tapatalk

[MilkIsYum]

Looks insanely clean. Is this the vr that had the 'engine rebuild' that was for sale?

Thanks! I'm really happy with the condition it's in for a 20 y.o car! (The manufacturing date is Dec. '95, but it's a 96 model!)

It was picked up off Gumtree actually, from out towards Cranbourne.

I feel like this is going to become a great thread

Cheers! I've been following your build, you've been doing a ton of awesome work.

[Juzzpc]

thanks man !! I appreciate it


Sent from my iPhone using Tapatalk

[AKA VR6]

Cant wait to see where this goes.

[MilkIsYum]

Donor Car:



Donor Car Engine Bay:



I did a test fit on a K&N filter from the donor car to see how it would look. It frees up a ton of space in comparison to the stock intake.





I removed the headliner from the donor car, but my main one has a sunroof and the donor doesn't. I think it will be a pain to try and make the headliner work. Ugh!

[stefcio007]

yep, removing the stock intake frees up heaps of space. Increases airflow around the engine and made it run slightly cooler. That's what I found anyway.

[HaydEn]

Don't run a filter straight of the maf. Add a length of pipe to get the filter down to the headlight at least

[MilkIsYum]

Don't run a filter straight of the maf. Add a length of pipe to get the filter down to the headlight at least

Is this to force more clean air into it?

[HaydEn]

Air less turbulent so the maf gets a more accurate reading

[MilkIsYum]

MK4 black leather seats waiting to be installed!

[stefcio007]

nice seats

[camhaz]

I have just completed an auto to manual conversion on a 4 cyl Mk3 and for me, the biggest decision centred around the engine bay wiring loom. They are different between the two cars. I decided to go the whole hog and stripped out the loom which required dash and brake booster removal. In the end it was worth it as the car cranked first time and everything is as it would have been from the factory except for the instrument panel which still has the auto indicator even though it is disabled. At least I retained my odometer mileage too.

If you don't use the manual loom, I think you are going to have trick the auto cutout into thinking it is always in neutral so it will start. It also means you have to retain the miles of auto wiring and will have to custom wire in the reversing lights and possibly the speed sensor on the gearbox. For me it was worth the effort as I don't know enough about auto electrics to confidently do that stuff.

Hope this helps. Rob.

[MilkIsYum]

If you don't use the manual loom, I think you are going to have trick the auto cutout into thinking it is always in neutral so it will start.

From what I researched, I should be able to connect the VAG-COM to the connector and reprogram the ECU from auto to manual. and pull/disconnect the TCM (auto control box, under the rear seats).

I found a post about the reverse light switch and the tach sensor.

VWVortex.com - Mk3 Golf Transmission swap: Auto to manual

Did you have to swap in a new starter? or was the original fine?

Thanks!

Edit: Plus, with swapping the looms I'd have to re-wire my sunroof controls into it as well, since the donor car doesn't have one. I'll probably remove as much automatic wiring etc. as possible. But should be okay with the original loom.