brap brap couple of videos of her alive =D complete with my dodgy accent haha

last jobs for today if it stops raining or tomorrow

* Fit rear exhaust rubber

* Adjust Gear Linkage

* Adjust Clutch Cable

* Add ground cable for temperature guage

* Wire up alternator live & on switch

* Pikey mod throttle cable so its usable

* Fit rear exhaust rubber - zipties and fuel hose

* Adjust Gear Linkage - 1st and reverse is A ok

* Adjust Clutch Cable - suicide clutch

* Add ground cable for temperature guage - NO TWISTING!

* Wire up alternator live & on switch - leave it off, more power

* Pikey mod throttle cable so its usable - suicide throttle

Should be driving in about 5 mins :)

lol, it stopped raining about an hour later ant so i was back out there!

throttle cable is done, fuel hose clamp and a bike throttle cable and its a win, secured the carbs with cable ties and undid the carb rubbers and slid them further onto the manifolds runners so its nice and snug now

alternators wired up, clutch is adjusted, ill adjust the gear linkage when i get it on the road, i think i can get 1 thru to 4th and reverse so thats good enough for now!

apparently the fan will come on with my current wiring, its just the rad switch and the fan switch that i need wired up, the 4 pin plug is just for the ecu and the temp guage. ideally i need the sender you have in yours with that loom plug and i can just wire it up like that

so tomo, have it idling on the drive, make sure fan comes on, take it out for a blat.

Arghhhhhhhhhhhhh! Fan is fine, it comes on, the old wiring was the thermostat for the hedgehog heater so is no longer used.

However, went to take it for its maiden voyage and senor fail arrived!

Anyone got any clues to why when I engage the clutch, this noise happens?

Mk3 CEG Gearbox, Mk4 16v Clutch & Flywheel, Brand new clutch cable.

Sounds like youve got the wrong clutch in there, the centre plate spline hole is too large a diameter than the gearbox input shaft. Have to whip the box out I'm afraid, take the clutch apart and check if the centre plate slides and holds on the gearbox input shaft.

Did this on a mates mk2 golf gti, schoolboy error, should always check the clutch fits the box! oops!

Hmmm,

Humer used a Mk4 Clutch & Flywheel in his 16v conversion on his Mk3 Polo with an 8P Gearbox,

I have a Mk3 Flywheel here thats unfitted and I've read that the Mk4 Polo clutches are the same as Mk3 ones anyway.

That's mainly the reason I chose not to change the Mk4 Fly & Clutch.

I've always thought clutches just die through slipping becuase of a reduction in pad material over time or from some contamination.

If I just push ever so slightly on the lever mechanism on the gearbox, I can here the noise of metal tickling metal, so I think you may be right.

my gear linkage isnt set up correctly and I'm just going to check that I've not done a school boy error and its actually in gear, that would be tres embarrising!

Edited 15 November, 200916 yr by grungeisdead

Did you put a new clutch in? Could just be that youve been givin the wrong clutch.

It def sounds exactly the same as the 1 i did a few years ago, that sound will never go away from my head, was a nightmare! lol

Edited 15 November, 200916 yr by turbodaily

nah didnt replace the clutch, just used the mk4 16v clutch that was already attached to the engine, as it was taken from a daily and I've never alinged a clutch before, i thought it was better using it to err on the side of safety

whats the noise you would get with a fucked clutch release bearing and what symptons would you get?

car was definatly not in gear as it would have driven through my house haha

and haha i know the feeling dude =P bastard cars

Edited 15 November, 200916 yr by grungeisdead

I goosed release bearing usually makes a rattling noise when the clutch pedal isnt depressed and the noise stops when it is depressed so i doubt its this tbh.

Best skin up, get out there and drop the box out, only an hours workn mate!

http://s134.photobucket.com/albums/q104/wi...nt=MOV02439.flv

http://s134.photobucket.com/albums/q104/wi...nt=MOV02440.flv

Just put up the right video for the snapshot above in your post above.

Did you use a 200mm clutch off a valver? Where was the relaese bearing from, the same clutch kit?

Hey man,

Cheers for the correct links, i didnt check them.

Yep I retained the valvers flywheel and clutch, left them in place so i didnt have to mess about with alinging a clutch.

I was going to put the mk3 flywheel and either a new mk3 clutch or retain the mk4 clutch, but I've never changed alinged a clutch before so didnt want to bring that extra variable into the equation.

I didn't change the release bearing, other than what was on the box i got from you.

Just had a read in the online haynes manual to see if i missed anything out.

I had problems originally getting the box onto the engine due to angle but when i titled the engine, the box just slid sweetly on.

I'd take it off but i wouldnt know what to look at. Would i need a release bearing from a mk4 to use the mk4s clutch?

Thanks!

also how are the clutch cables adjusted on these, the cable is fitted correctly, i withdrew outerlock nut (nearest to the fan shroud) and tightened the inner locknut with a 10mm spanner until i got some pedal feel. it still feels a bit dodgy now.

the haynes is rather vague and the mk1 golf ones arent self adjusting like the polos

ps. ill probably whip the bastard box off tomorrow, not had dinner yet and negged out with cars atm, might do the public transport commute tomorrow! eek

Edited 15 November, 200916 yr by grungeisdead

Saf, i took the release bearing off that box because it was shagged and assumed you would be putting on a new clutch assembley. I thought that noise sounded like the fork arms scrapping against the clutch plate fins!

Doh!

you are a fucking chump saf !

Not check for stuff like that lollllzzzz

haha ant you motherlicker

assumption is the mother of all fuck ups as they say,

ill get a new one ordered tomorrow morn, misssssssssions.

so close, yet so far haha, cars are gheyorz

will report back tomorrow

Dropped the box, got the release bearing from my 4 speed box fitted, but now can i get the box back on the fucking engine, no!

mcfuckinshitwankers

given up on it now, but i think tomorrow I'm just going to disconnect, the exhaust, coolant pipes and fuel lines and just rip it out of the bay, stick the gearboxentwatten on when its out the bay and drop everything back in.

i hate cars

grind a straight onto the o/s flange and it will slip over flywheel, otherwise you will be there for ever, took me an age to get it on and i figured for futurre ease, just grind the flat on the flange. pick a bit between the bolt holes.

and I'm saying nothing about the lack of release bearing!!! huge NURSERY boy error!

good luck. engine hoist doing well for you!

ant hows the budget beast? come and show me what you have been doing.