'89 Mk2 Golf GTI 8v -> ABF -> VR6 -> VR6 Turbo

I like it & a good topic with how to info

 

Updates will be slow this year but im doing bits when I can.


I bought some longer bolts to go with the 5mm spacers. These are only 3mm longer but the next size would have needed cutting down.


I bought some chrome gearbox mounts months ago and forgot about them so fitted those today aswell.


They look good but the rest of the bay lets it down, it needs a good scrub when the weather improves.


The Jetex system I have is designed for the big bumper model so it sticks out too far and hangs too low. For now I wanted to at least get it sitting a bit better, so i've extended the rear hanger by 20mm.


I could only find red paint but it won't be seen anyway.


Fitted. I need to invest in some chain hangers, these are starting to perish.


It sits better but I need to disconnect and rotate the whole back box, the left pipe is 10mm too low.

Other than that i've fitted a keyless central locking kit and have the interior a clean. I will get some pics next time.

 

A couple of pics from the end of last year.

 

Just read your entire thread - brilliant effort. Now to crack on with mine again...

 

Bagged myself a refurbed genuine Bosch Mk3/Mk4 starter as mine was already a bit sluggish.




The new starter has one extra terminal, not sure what its for? So ive just ignored it.


It spins over well and starts in under 2 seconds, it used to take 4-5 seconds.


Ive got a catch can and breather plate to go on as well. The plate will be drilled for an AN12 fitting.


Im going to make a custom shroud for the rad to hold a couple of slim line fans and mount the catch can onto.


Going to use some beefy AN12 fittings and braided hose.




Ive finished the central locking install and replaced the door membranes.


The heavy Jetex system is eating exhaust rubbers, ive heard about chain hangers but cant find them anywhere so ive improvised with some cable ties.


Looks like a bodge but it works well.

 

This project is taking a slightly different direction now. Hate all you want but im fitting big bumpers and a VR6. It's my car so I will ruin it if I want to


Refurbing the front bumper.


Looks pretty good.


Magnets to hold the front plate.


Painted the front bumper iron with POR15.


Bolts for the front repro bumper so I can remove the skin, leaving the bumper iron in place.


Front fitted. I still need to do the rear bumper, skirts, trim and G60 arches.


Got a great deal on a complete VR6 2.8 AAA setup.


Still no engine crane so had to improvise to get it on the stand.

The plan is to tidy up the VR6 and maybe fit PAS at the same time. Not sure if manual steering would be a bit silly with a VR?

 

That texture spray looks like it did a great job! If you put big bumpers on it you have to get all the big bumper arch trims, side skirts, and door trims too. Looks like a bodge otherwise.

 

Thanks Luke, you can buy ProXL from ebay for about 12 a can.

 

So the engine needed a bit of a tidy up.


I spent a couple of evenings degreasing and cleaning the block with various wire wheel attachements.


It came out really nice, I used halfords VHT matt black (brush on). The sump will be replaced and the head (and all ally parts) will be cleaned up as best as possible.

Nice little before and after:









I fitted a brand new water pump with a metal impeller. I want to replace as many bolts as possible with brand new ones and either replace or clean up all of the ancillaries (depending on cost).

To do:

Finishing cleaning and building up the engine
Replace timing chain and guides
Shallow sump, hopefully a mk5 R32 sump + pump
Refurb and fit the Mk3 subframe
Fit engine
CE2 wiring conversion

Then I really need to decide if I want to swap over to PAS. Not sure how I will tension the belt without a PAS pump anyway.

 

Mini update to show todays progress.


Bought a mk3 Golf subframe and ground it back using a knotwheel.


Chopped off the bits you don't need when fitting to a Mk2.


3 stage POR15.

I have also cleaned up more parts ready to bolt on.

The next job will be to replace the timing chains, replace the clutch and clean up the gearbox.

 

Looks great, where are the skin bolts fitted, behind the plates? Im due to do similar.. and those magnets will hold?

 

The bolts from behind through the genuine iron and into the repro bumper. I can remove the skin in 2 minutes, leaving the iron in place.

There are 8 neo magnets behind the bumper and 4 on the back of the plate. They are strong enough to hold the weight of the bumper off the plate.

 

Until I get hold of the timing chain and clutch kits there isn't much I can do so im just spending a bit of time tidying up the engine.




Painted the water and PAS pulleys.


Painted the bottom pulley in place as its sounds quite challenging to remove.


I still need to clean up the PAS pump and find some new bolts for it. Its starting to come together, I still need to paint the sump and clean the head.


Made a start on cleaning up the gearbox.


Test fitted the new rear bumper.


I think I will need to make a new hanger bracket though!

 

Gearbox cleaned up to an ok standard. It needs a bit more work in the hard to reach areas. I also found a polished mount that I bought a couple of years ago and never used.


The previous owner over tightened the oil filter cap, to the point where it wouldn't even budge with a breaker bar! Eventually the plastic 'nut' deformed and I had to use alternative methods.


Good news is I got it undone but I do need a new cap


Painted it satin black. Does anyone have the part numbers for the 3 bolts that hold it on?


Sanded the dipstick tube smooth and painted it black.


Cleaned up the PAS pump and painted the end bit silver to freshen it up.


Anyone have the P/N for new bolts?


I bought a brand new Veleo alternator but its physically smaller than the old Bosch unit. Any ideas? Its definetly for a VR6 and it fits, maybe a low/ old spec model? Either way it should be ample for my car that doesn't have A/C or even a sound system.


Blocked the holes for the CO sniffer pipe.

Sorry for the baby updates but I need to wait for pay day to get the timing chain and clutch kits.

 

As much as I want to do as you have done, 30mm llwer with lower spoiler on bib bumpers and it scrapes a lot. My old bumper and wpoiler never quite firted as well as yours and the only solution I found was to use the rubbery cable ties to hang on to spoiler as it dislodged

I wont be putting the spoiler on for a while.

 

Cheers for the help on here and on FB John!


Quick update, sump gasket is seeping so im going to clean the sump up, weld on a quick minimal effort sump guard and bolt it back on with a new gasket and bolts. Eventually I will get a mk5 R32 sump when I can afford it.


Sump off. All looks nice and clean in here.


No crap or bits of chain guide in the sump which i was very pleased about.


Sump guard made from a piece of 5mm plate. I've bent the front lip up slightly and bent the edges around to match the contours of the sump.


Why not Its temporary.

 

Funds are low until payday so im just doing the little bits I can for now.

Made some improvements to the sump plate, i've added more folds and got it sitting flatter on the base of the sump.









Im gradually replacing all bolts for new ones to keep things fresh:







exhaust studs were good enough to reuse so I just ran a die over them and fitted the manifolds with new gaskets and nuts:

 

Sump on. Timing chain up next!

 

Last look at the ABF in the car.


A nice shot showing how I routed the wiring.


ABF out. The bay needs a bit of a tidy up but its kept well tbh. Brake lines need re-bending to make them neater.


Old subframe out.


VR6 subframe built up.


fitted.

Next few job:

Fit new timing chain kit
Fit new clutch kit and the gearbox
Fit PAS rack
Fit mk3 shifter box
Tidy engine bay
Fit engine