Well I have purchased my donor vehicle :)

So I have been busy in labelling the engine with useful info like 'This goes here!' :)

The Mk2 is up on ramps and so far I have removed the radiator and the exhaust.

More fun over the weekend!!!

Mark

how did you get on with the labelling and undoing stuff?

more this weekend?

we want pictures!

Well a bit more labelling on the Mk2 just in case I want to put the original engine back in. I have also removed the gear linkage and fuel feed and return from the engine. I will be totally removing the engine from the Mk2 this weekend... I hope..

Pics :)

Also as I have been really board at work this week I have been creating a MS Project of the whole Project. Which Is really just a todo list of everything and stuff that I am buying and when they are going to be replaced. It has kinda been interesting in a geeky kinda way!! :)

Mark

Edited 7 December, 200718 yr by max_crox

Just felt like giving a bit of an update of where the whole project is..

Well Engine from the mk2 is still not out but its getting there.

So far I have:

Removed Air filter/Intake

Removed the Radiator

Removed the Exhaust

Removed the Fuel feed and return pipes

Removed the gearbox linkage

Removed the coolant system pipes to and from the heater

Removed and labelled all the engine bay loom

Removed the pipe from the header tank

Removed earthing straps

Removed Accelerator cable

Removed Clutch cable

And taken hundreds of pictures

So i just have to get it back up on stands and remove the Drive shafts from the outputs and the the mounts and hopefully it should just jump out. :-D

Now I just have to do the same for the Mk3 and take off the steering damper and put it all back in the Mk2. I'm going to replace the cam belt and water pump whilst the engine is out as I don't want them to fail at any point whilst tracking it. Also all of the engine bushes will be replaced along with all the gearbox parts identified in this FAQ. I was thinking about fitting a short shift kit from Advanced Autosport but I don't think finances will stretch to it at the moment. Before putting the engine in I am going to give the whole engine bay a clean and perhaps a paint in its original colour.

The other things that I am swapping over from the Mk3 to 2 are:

Fuel pipes - fuel filters replaced

Tank and pumps - tank rust proofed

Rear Axel - with replaced G-Lader bushes

Hopefully I can get this done for the 26th of Jan for the rolling road day but I have a deadline of the end of Jan to get rid of the Mk3 other wise the wife might get rid of me!!!!

Things that also will need to be done and replaced are:

Swapping the Suspension for the G40 items

Fit front lower GED Brace

Fitting braided brake hoses

Fitting Exhaust system and 4-2-1 Manifold (still need to purchase)

Add Brembo Max Disc's and Green Stuff pads

Relocate the battery to the spare wheel well

Purchase wheel spacers and a pair of tyres.

Interior wise the rear has already been stripped but I am looking for some cheap-lightweight buckets and some harnesses.

Further down the line after a year of tracking I will look into replacing the bonnet and boot with fibreglass items and poly-carb for the windows but we will see.

Any way... thats the end of my Essay :)

Some Pics, 5 from hundreds :)

Mark......

Well the engine is finally out.. :):):):):)

And it is now sitting in my nice warm garage. I managed to do it just in time as it started to piss it down.

Jobs for tomorrow are to removed the loom and give the engine bay and engine a dam good good clean.

Mark

Edited 22 December, 200718 yr by max_crox

Well had a bit of a lie in today so I didn't manage to clean the engine bay but I did manage to removed the loom. :) Here are the pics :)

This is basically how the car will stay now until after Christmas.

Mark

I got a really cool Christmas Present :)

SO I though as I have another week off work I would give the engine bay a clean.

After the first pass it looked like this

Then after a lot of this

It now looks like this :)

Hopefully by the end of the week my other really cool will have turned up. My wife has bought a load of spare parts from VW :) I like Christmas!! :)

Edited 27 December, 200718 yr by max_crox

wow that engine crane looks like its seen better days, my dads one is pretty old but that looks shagged.

is that a GT i-drive cross-country bike i spy? weird how lots of polo owners also do a bit of riding about in the woods.

making pretty good progress man, what you doing with the old lump, keeping for spares or what?

whats up next, bit of smoothing and rust curing in the bay, bloody spaniards?

wow that engine crane looks like its seen better days, my dads one is pretty old but that looks shagged.

is that a GT i-drive cross-country bike i spy? weird how lots of polo owners also do a bit of riding about in the woods.

making pretty good progress man, what you doing with the old lump, keeping for spares or what?

whats up next, bit of smoothing and rust curing in the bay, bloody spaniards?

Its a borrowed crane that I think has been stored out side for the last 10 years :) I'm going to give it a rub down and a lick of paint when I'm finished with it.

It is indeed well spotted... The company I work for have taken part in the Cycle 2 Work scheme so I decided to get a nice new bike though it. I haven't used it much as I'm working on the car!!

I'm going to keep the old lump 'just in case' trying to work out a way to suspend it from the ceiling in the garage so it wont take up space... :)

Yep you got it in one... The engine bay isn't too bad.. but there are some small bits of surface which I'll have a go at this week. I also if to take some parts of the donor car to sell and then this weekend if the parts for VW turn up I'll get the donor engine out.. Weather permitting :)

Mark

haha thats crazy, i've done that cycle to work scheme aswell, working for halfords makes it even cheaper aswell.

i look forwards to the pictures, just outta interest the G reg coupe S i bought recently has a huge rusty hole in the battery tray, not noticeable unless you whip the battery out and take the trim off inside below the steering column, might be worth a peak.

Cheers... Yep it is a bit rusty round the battery area but I cleaned it up and wax oiled it. I'll get the trim off tomorrow and see if there are any holes... I am relocating the battery to the boot so hopefully that will stop the water build up.

Mark

Just a thought Mark, but why not relocate the battery on the floor behind the passenger seat? Ok, it'll limit the rearward travel on the passenger seat but there are good reasons to do so.

Firstly, you don't want to move the battery too far from the starter motor because otherwise you will need to use a heavy guage cable to reduce the current drop. To safely and tidily route a cable from the spare wheel well to the engine bay will probably use around 3 mtrs. of thick cable. Not only is this expensive, but it is heavy too.

Secondly, as you rightly state, it is good to remove weight from the front (particularly high up). However, I think it would be better to keep that weight between the wheelbase and low down. Just behind the seat is nice and low, and with a shorter cable run you should be able to select slightly lighter guage (and weight) cable for the job.

Just my opinion Mark.

Its a great job you're doing there, keep up the excellent work and good luck with the GT conversion.

Cheers,

Richard.

Just a thought Mark, but why not relocate the battery on the floor behind the passenger seat? Ok, it'll limit the rearward travel on the passenger seat but there are good reasons to do so.

Firstly, you don't want to move the battery too far from the starter motor because otherwise you will need to use a heavy guage cable to reduce the current drop. To safely and tidily route a cable from the spare wheel well to the engine bay will probably use around 3 mtrs. of thick cable. Not only is this expensive, but it is heavy too.

Secondly, as you rightly state, it is good to remove weight from the front (particularly high up). However, I think it would be better to keep that weight between the wheelbase and low down. Just behind the seat is nice and low, and with a shorter cable run you should be able to select slightly lighter guage (and weight) cable for the job.

Just my opinion Mark.

Its a great job you're doing there, keep up the excellent work and good luck with the GT conversion.

Cheers,

Richard.

Umm definitely food for thought.. I see what you are getting at.. I'll have a check to see what the leg room is like with the battery (and battery box) behind the pass seat. This also might help to balance the car out from left to right as well... Cheers for the input

Mark..

Well I got a phone call from VW today my parts have arrived... also I got a water pump from GSF £22 with my discount! :) These are my Christmas presents from the wife... she is great isn't she!!! :)

Also as the car fund is getting a bit low I thought I would take some more bits off the donor car to sell to perk up the funds. So I set about taking the arch trims off and this is what I found

One reason why these arch trims are staying on my mk2 :)

Well it has been a busy day today.. Was out of bed by 9.30 and working on the car by 10am :)

I started by removing the the radiator. You probably don't need to do this as there seems to be loads of space but I did it just to make sure there was enough room.

I then started on removing all the wire connectors, Speedo cable, Clutch cable, Accelerator cable, header tank and coolant pipes.

Then after getting some well needed funds from the sale of the rear seats it was off to Halfords for some more axle stands. The exhaust (from the cat back) has now been removed as well as the gear linkage. I can't seem to remove the Lambda probe, so I might have to apply some heat to it.

My plan was to get the engine out by then end of today but after a slight miss hap with the axle stands that was out the window.

Tomorrow I'll get the engine out and replace all the bits and bobs that I have purchased.... hopefully!! :)

Mark

Nice one Mark, glad to see you've been busy again!

Yeah, relocating the battery behind the passenger seat is also helping to balance out the car. If you really need to keep the passenger seat rearward travel, then you could mount the battery directly behind the footwell up on top of where the rear seat sqwab would be (assuming you will be removing the rear seat?). Ok its a bit higher up, but still better than the spare wheel well IMO.

What was "the slight mishap with the axle stands" then?

......What was "the slight mishap with the axle stands" then?

Cheers.. :)

Well I was jacking it up to put on stands one side at a time and it decided to half slide off to the side.. giving me a brown boxers moment..

so it took me a while to sort that out.. :)

Mark...

Looks like good work you're doing for the 'S Mark! Nice to know that the money for the seats came into good use!

Looks like good work you're doing for the 'S Mark! Nice to know that the money for the seats came into good use!

:) Cheers... It was really nice to meet you.

Mark

It has been a productive day today.. :)

It started with this :)

Then after I had removed the drive shaft bolts and engine mounts it was time to remove the engine.

I then started on the wiring loom but as on the Mk2 fuse box had bolts on the back I thought I would take out the passenger seat so I could get better access, only to find that there wasn't any!! which isn't too bad as I'm going to have to take them out to sell any way.

I then set about putting the GT wiring loom into the Mk2.

And here it is all fitted!! :)

Tomorrow I'll be putting the GT engine up on the engine stand and replace the water pump and the timing belt. I also want to de-wedge the throttle body so I may do that as well.

Also after reading a thread on here about fitting the Passat master cylinder I am toying with the idea to fitting one while the engine is out.. hummm.. :)

Mark

After a well deserved lie in I got started on replacing the timing belt and water pump..

But can I get the bloody water pump off????? All 3 bolts have been removed but I can't shift the dam thing... I have left it to soak in WD40 and hopefully tomorrow I can removed it.

So not much to report today...

The water pump is finally out!!!! :) was well happy!!

The weapons of choice, a sawn off drive shaft bolt thingy and a rubber mallet

As you can see it was a bit corroded inside. Also the old pump had the plastic propellers so I am glad that I have changed it.

After cleaning the face of the face of the block off I put in the new pump...

... And then the new belt

I am now waiting on some parts from VW so thats as much as I could do today so I decided to give the engine a bit of a clean with Autoglym Engine and Machine Cleaner.

So as I am back at work at work tomorrow (Boooooooo!) I wont be able to do any more work on it till the weekend. I am going to replace the manifold studs and nuts as I am going to be fitting a new manifold over the next couple of months so I'm thinking that if I do manage to snap the studs then it will be far easier to work on replacing them with the engine out of the car.

Woah you've been busy chap!! good effort with getting all that done since I last checked this thread. If you need a hand with the conversion I'll be more than happy to help, although you seem to know what you're doing!

I'm doing the vented disc conversion 2moro as well as top mounts and rear engine mount. All in a day with a trip to GSF.....gonna be interesting to say the least.

Woah you've been busy chap!! good effort with getting all that done since I last checked this thread. If you need a hand with the conversion I'll be more than happy to help, although you seem to know what you're doing!

I'm doing the vented disc conversion 2moro as well as top mounts and rear engine mount. All in a day with a trip to GSF.....gonna be interesting to say the least.

Cheers :)

Well I wouldn't say I know what I'm doing as a lot of the stuff seems to be straight forward... I hope. Cheers for the offer I may need it when putting it back in! :)

Well make sure you get your discount and wrap up warm as it bloody cold!!! :)

Mark

TOP TIP COMING YOUR WAY i've just done a gt conversion in my mk3 cl, and have had a few electrical problems and it turned out to be on of the loom plugs that go through the bulkhead wasnt clipped in properly and caused me no end of problems!

make sure yours is clipped in!

rob