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Managed to get the snapped stud out of the turbo today with the help of a welded nut, and almost stripped the engine right down ready for cleaning. Found a few issues but all minor. The turbo coolant supply has been cut but I think I can jubilee clip a new one to the metal pipe. Also found two missing manifold studs. Looks like someone has changed the gasket recently and then gave up. Nice surprise was that the gearbox I thought was a six speed, turns out to be a five speed EHA. It has long ratios so I might swap it but it's good I don't need the hassle of selling one and buying one. Another nice surprise is that a single mass flywheel has been fitted. Degreasing and painting next.
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Well ill start this off with a big thanks to joem83 for the heads up. The above advert was still up and a road trip of immense proportions started on saturday, Glasgow - Sheffield and back in an Arnold Clark van. Got there and much to the promises of the lad there was no crane and the block was still full of oil. We managed to manhandle the engine into the van with a half-bust trolley jack and our massive biceps. Rolled it in.. still full of oil. Nice shiny 900-mile-old Arnold Clark van was now swimming half an inch deep in the back. Cat litter and a £14 excess avoidance charge led to it being filthy but accepted back. So, AUQ engine, 6 speed box (for sale, i want a five speed), Radiator, and some other bits was the result. All minging and covered in oil. Last night I set about deleting the complete PCV system, aircon is removed, mounts removed to fit a new timing belt (as this was quite new but now covered in oil). It needs a few bits such as a dipstick tube, EGR blank etc but it also has the bonus of all the loom still being fitted. It was snipped at one end but with all the plugs still being fitted it means it should be more simple to splice into the ECU. ECU, downpipe and a few other bits are all thats left to get to make it complete. Any 1.8t gurus on here? I could really do with guidance as to what pipes form the PCV system. Ive pulled the secondary airpump but there are hard metal pipes that run under the injectors and are additional to the fuel supply and return. I'm presuming it runs to the N75 valve, so if so they're coming out too and ill pop a resistor into the connector. In an ideal world I would like to run about with no EML, but time will tell.
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Last Edit: Jun 5, 2017 10:53:30 GMT by oasis6x
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May 31, 2017 10:06:07 GMT
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I know, it really doesnt weigh anything. I can roll it in and out of the garage so easily.
Long term I'm going to have to get some wider front tyres on it and track tyres to make it worthwhile. ill have to ditch the 6 speed box off it however as it will foul the chassis rails, I'm looking to get an ASD in it from a mk3 golf. The ratios are nice - 72 in second should be possible with 14"s and the final drive is nice and long for sitting at 70.
ASD Gearbox
• 1st 33/10 = 3.30 • 2nd 35/18 = 1.94 • 3rd 34/26 = 1.31 • 4th 36/33 = 1.09 • 5th 33/46 = 0.71 • FD 60/19 = 3.16 • Driveshaft Flange size: 100mm
once again thanks for the heads up.
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Last Edit: May 31, 2017 10:12:00 GMT by oasis6x
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May 30, 2017 14:52:44 GMT
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update, engine inbound! 180bhp AUQ
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May 30, 2017 14:52:04 GMT
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Some progress so far. Finally got the block and gearbox out, without a crane! By hand and tbh it was pretty easy. Doesn't weigh a lot. Bucket seats are in hand now and it looks like I'll have to get proper Lupo mounts for them tbh, it seems the easiest thing to do. Driveshafts are still attached as they are on with some crappy vw 12 pointed bolts. The rails are now exposed and the grinder will be out soon to cut all the chaff off and make space for the engine mounts. You can actually buy the mk4 gold mounting point from vw for £24, so that's getting picked up tomorrow. I missed out on a whole engine and box on eBay for £150 too which I'm a bit gutted about. I'm erring towards finding a mk4 remapped golf and just using it as a donor car, accepting my power will limit about 180bhp instead of starting there. Not sure yet. Plan now is to sell the box on eBay, convert the block into four paperweights and then clean and shave the bay. Mourning the engine isn't daunting.. however the wiring is.
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Nearly at the point of just the block and box left. Driveshafts need removing and then it's coming out. Tell you what I wouldn't want to have to change the power steering pump on one, it's hard work when it's right in front of your eyes! Got the back of the car full of bits to go on eBay.
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Mar 28, 2017 12:02:03 GMT
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Potato was intentional!
The quality of the photo does indeed look like it was taken on a iPotato.
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Mar 28, 2017 10:11:18 GMT
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Halfords did 10w40 for £11 a gallon.
I let the engine drain overnight, pulled the filter, refilled with curse word oil.
Gave it 100 miles and did it again, oil is now lovely and clean and gunge free. When i drained out the first time the oil looked clean tbh as did the filter. I presume it all dissipated.
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Taken on a potato by my mates dad;
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Thats the plan. I did manage to get everything else off the block last night - and even sold the head on ebay for £65 so thats a good start.
I suppose I had better get my finger out and list the rest.
Buckets and harnesses should be turning up in two weeks too.
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Mar 27, 2017 12:44:38 GMT
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I'd be tempted to get some dynamat or equivalent up on the roof, should make it a bit more pleasant, especially in hot weather. Also, in winter you'll get condensation that will drip, so may help with that. If you're pulling the dash too, dynamat on the firewall will stop the heat getting into the car. I messed up there, you spotted it. When i was stripping it, it had a nice piece of cardboard on the roof siliconed in. I got a bit ahead of myself and pulled it, halfway through i wished id have kept it
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Mar 27, 2017 12:24:54 GMT
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From what ive worked out, I just need to snip the current engine loom and bridge in the 1.8t loom. As its VAG-VAG they share a lot, and looking at the wiring diagrams its only about 16 wires for the sensors and the injectors.
Not really a lot to do when i think about it like that, i get to retain all the current lighting looms, fan sensor, ECU plug and more importantly the current dash and ingnition system.
I think I'm going to end up pulling the dash in order to do it properly, and yeah it is quite well documented just not with a 'guide' as it were. More like pointers. A loom is available off the shelf to do it but its £400 (made really for some wiring).
Electronically I need to splice in the Golf pedal as its flybywire, splice in the 1.8t sensors and rail to the Golf ECU. It will need a few sensors adding such as MAP i think as its forced induction from NASP.
Or all that could be a load of balls haha
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Last Edit: Mar 27, 2017 12:25:54 GMT by oasis6x
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Mar 27, 2017 12:20:18 GMT
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Looking at this thread made me more interested in sorting out my 1930s knackered and botched timber side opening doors. I have a Howdens down the road and just gave them a phone, yeah you need trade but the woman on the phone said I could blag it saying i was in any trade.
she wouldnt however give me prices, if i get some prices / buy some doors ill post what they're like. They said they supply softwood for painting 6.6x7 or 7x7.
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Mar 27, 2017 11:31:29 GMT
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guaranteed cheapest prices in human history, chipping away at the engine bay before installation of a 1.8t
all parts available, engine, box, inlet, electrics, sensors etc
thanks
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Mar 27, 2017 10:19:09 GMT
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T plugs are the little square plugs, theres also T10 or T14 depending on what year donor you use. I've been mating my mk2 loom up today and do yourself a favour, don't cut the blue square plug off the dbw loom like i did LOL Ahhh.. sorry buddy totally missed your response there. Ah right yeah the whole loom is made up of them, I'm not sure actually where to start with it if I'm honest. I need to get amongst a wiring diagram to see what I can actually match up, and what i can snip without causing constant EML. Ill have to have a good look at it before I put the engine in, as much as i would like to just leave it alone until last. How have you done yours? spliced the 1.8t engine loom into the lupo loom?
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Last Edit: Mar 27, 2017 10:20:23 GMT by oasis6x
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Mar 26, 2017 18:05:57 GMT
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Bit of an update now. Work was suspended a bit as I did the headgasket on my daily. Completely stripped dash back now with most of it binned. One seat remains for now. I decided to strip the bay and eBay it all to pay for bits of the conversion and beer, so I've been methodically stripping the thing and binning the rubbish. Down to the block and box today before my back gave out. Next steps are removal of the bumper, wings, front slam and then the rest of the bay. I'll probably weigh in the block and make some nice paperweights out of it. Once it's all stripped its coming out for a long wash and a polish then the install can commence. Mk4 golf is the donor.
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Last Edit: Mar 27, 2017 10:19:46 GMT by oasis6x
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Yeah its been a pleasant job tbh. Car is back up and running now, first turn of the key.
Turned out halfords had an oil sale on 10w40, add a trade card gave me £11 a gallon.
So you reckon run it about a few miles and then just do another oil change?
I do like these engines. New HG and they're right as rain.
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Pour a gallon of diesel in it and run it for 5 minutes then drain off it'll be spotless. Used to do it all the time. Surely diesel will just eat my rubber seals? Think I'll try the cheap oil route
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