VW MK3 GOLF 8V TO 16V CONVERSION

[golf3]

Today went wonderfully!

After getting some great advice over the phone from loon.. (which should be charged at $4.95 a minute, it's well worth it!!!)

I fixed the timing belt after realising it never slipped, it was just installed incorrectly...oops...

I then did a compression test on all cylinders to check for bent things...

Cylinder one - 150psi
Cylinder two, three and four - 200psi

That's within tolerances, so I'm not going to worry about it...I will keep and eye on it though.

After putting everything together, i started it!

It idled smoothly, although a little high at 1400rpm...
I ran it for around 20minutes, with a loud ticking noise, but that will go away within 200km's i've been told.
The temperature guage worked, and the thermo fans kicked in. Which is great because I will need those in summer.
There was a little bit of smoke out the exhaust and on the exhaust manifold and downpipe, but after the oil and crap burnt away, it stopped.

The plugs were dirty, so i gave them a clean, and after trying to crank it over a few times, the battery died...I've placed that on charge overnight...

It's really wonderful that it has started, and I can now see the light at the end of the tunnel...

Thanks to all involved...It will be driving soon!!

[Golf Loon]

Nice work Sean. I reckon you earned that Bourbon

Check the oil level tomorrow, then get it warm and hold the revs at 3000 for 20 secs then rev it, then do it again. That should quieten the lifter noise.

The idle is adjustable downwards. At least its running.

Can wait for the 1st test drive report.

Well done Mate.

[Tim]

woo congrats sean!
Im envious. Cant wait to get elbow deeep into my car!

Do you have everything u need to complete the job now? How did u go driveshaft wise? are the old ones compatible?

[golf3]

yeah, i hooked up the driveshafts ages ago..

i first compared diff housing and flanges when i got the 020 out and sat it next to the 02a...

[Tim]

awesome! I think another melbourne cruise is gonna be on the cards soon!

[golf3]

Well, today I had the first drive!
Although I only took it up the street and back...

I have some issues to work out though...

It's getting too much fuel it seems, which covers the plugs in crap, so everytime you run it, you need to clean them...

The idle was still a tad high, but i think that has something to do with fuel.

On the motronic 3.0 system, does the water temp sensor affect idle at all, as that sensor broke, and is not hooked up...???

And I'm throwing up the following codes as well..

00523
IAT Sensor - Temp High - Circuit Low - G42

00522
Engine Coolant Temperature Sensor -G62

00519 P0106
MAP Sensor - Out of Range -G71 B - Voltage Low -G71 A - Voltage High -G71


Tim has a photo of the car on the road...

[Golf Loon]

Is it a sensor with 4 wires? It probably controls the choke, which would account for the sooty plugs and it running rich. I`d be getting a new sensor.

Did it go ok though?

[golf3]

The sensor has two wires going into it...

Photo's courtesy of Tim... (thanks for your help buddy) (and that's my brother in his goofy hat)

[golf3]

The speedo doesn't work either...

[Golf Loon]

Is the speedo wire plugged in? Should be a 3 pin connector. That will have implications for your fuelling if its not working.

Take the sender out of the gearbox, as they are very fragile and it may have died. I just changed one on my VR6 and it cost me $70,

Looks sick driving round with no bonnet though. NICE

[joshyd-mk2gti]

your so close to getting it back on the road dude. good job!!

[GoLfMan]

looking good mate!!! not long to go now

[Valver.]

Have put some pics and help for you here, mate:

http://forums.vwvortex.com/zerothread?id=2756070

Goodluck with it

[Golf Loon]

Nice writeup Valver. geez your engine bay gives new meaning to the word detailed!

Why not write it up here and add to our knowledgebase. Cut and paste is ok?

[Valver.]

Your motor is a Digifant 3.1 - pre '96, no immobiliser, which is why it started up

High idle is a "limp-home" feature according to the VW ABF workshop manual. I s'pose the ECU winds up the idle as it must be unstable at 850rpm (vaccuum leaks probably cause this...).

The running rich problem could almost anything You're best to connect up all the sensors and wipe the fault codes and then see which codes come back up and also whether the motor still overfuels.

Chances are it's just very grumpy because it's missing a few things - so probably not a big deal.

Next up, check your vaccuum line setups against mine...

Just went out and took as many pics as I thought would be useful to you. Sing out if you need more...

THIS MIGHT HELP YOU WITH OVERALL REFERENCE OF THE ENGINE BAY. REMEMBER THERE MAY BE A FEW DIFFERENCES BETWEEN THE 3.1 AND 3.2 ENGINES:



MY THROTTLE BODY IS THE DIGI 3.2 VERSION SO MAY BE A BIT DIFFERENT:



THE BREATHER SETUP ALSO HAS A VACCUUM LINE FROM BENEATH THE IDLE STAB'N VALVE - SEE WHERE IT RUNS FROM THERE TO THE BREATHER TRANSFER: