Author Topic: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto  (Read 6851 times)

Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #60 on: December 29, 2017, 05:30:26 PM »
Headline news:

It runs!

Let me go into a bit more detail of the past few days events, as they’re a bit of a mixed bag to say the least. To begin, I decided that instead of re-using the bend, rusty old power steering pump that I’d buy a brand new one. I also ordered a new alternator adjustment bolt as well as some brake line clips and new allen head bolts but those didn’t arrive in time so had to source them from a secondary supplier:



So been out and under the car (more specifically sat in the driver’s wheel arch) and started fitting everything back up and fitting new stainless bolts where I could:



New belts were going on as well, got the alternator on with new hardware nicely:



At this point I decided that I needed to confirm the engine would in fact start up and run despite the water pump not being connected up, wanted to justify carrying on with the engine at this point. Got the battery connected, turned the key and after just a few turns of the engine it fired straight up! Was really happy with it, even though the idle was WAY off (about 2500 RPM!) and no air flow meter connected she idled smoothly. Quickly adjusted the idle down to about 1200 RPM and it ran lovely, much better than before when it was lumpy and sounding like a muscle car. There was some smoke coming from the back of the engine where the manifolds are, not sure if it’s stuff burning off (grease, oil etc.) or whether I have a leak at the manifold somewhere on the exhaust side of things but didn’t bother me too much. Then I heard a horrible metallic rattling sound and panicked thinking something had gone massively wrong… Was just the bonnet stay fouling the fan on the alternator! Note to self, work tidy.

So, after this victory I wanted to fit up the water and PAS pumps and get everything running to check for leaks as I also replaced both cylinder head flanges as well as the two coolant temperature sensors (black and blue) for peace of mind. I re-used the old ones as a temporary measure but they leaked badly so stopped cutting corners now and doing things right from the get-go. Ran into a snag when I couldn’t move the power steering pump bracket enough to enable me to fit the new belt. First I tried to undo the bolt at the bottom of the bracket (bottom right in this image):



It wouldn’t budge at all, totally seized on and going no-where anytime soon. That and the fact the top allen head bolt is rounded means this bracket it practically welded to the block right now, so I removed the pump from the bracket (suspending it out the way securely) and tried wiggling the bracket by hand to free up the threaded bit that connects to the bottom of the water pump bracket…



FYI, this isn’t supposed to be like this! Sheared the bolt clean in two, with the lower bit left in the bracket. So now I’m going to have to figure a way to get it off the block and replace everything. Normally, a lot of people would agree this is a set back and a bit of bad news but for me it was just Hayley telling me she wants upgrades (she heard me say I have them):



This is the Mk3 Golf GTI 8v PAS pump and brackets I got originally for the 1.6 to 1.8 litre conversion on Harriet (the other Mk2 that I still haven’t worked on for ages) which was then destined to be transferred to the VR6 engine but now it looks like it’s going on this car. This means that she’ll now run the upgrade to PAS which is always nice as I’ve read that the Mk3 PAS pump is much better than the Mk2 one so just need to figure out what other hardware I need in order to connect it all up, including replacing the water pump and brackets too.

So there’s more (aren’t you lucky today, reader… or readers? Leave a comment and let me know who’s following this build!). Went to sort out the front brakes too as figured it’d be nice to have the car able to at least roll on its own 4 wheels should the need arise (like to move it outside while I burn off grime and avoid gassing myself out). Gave them a paint and got new seals for them:



As I was refitting one of the pistons, I must have snagged the dust seal and tore it apart so needed to replace it. Now, logic would dictate at this point that buying a £10-ish set of seals would be cheaper than upgrading to a complete G60 setup (hubs, calipers, master cylinder and servo, the works) but no logic here, decided that it was a sign that I should just fit the G60 brakes and 16v hubs I have sat under the bench and stop wasting time and money on the 239mm brakes. I also have all new pre-bent copper lines for the front setup and I have a 9-inch servo in the pile of parts back in Essex but will need to source a second one as I want to run one on Harriet for my RS2 twin piston brakes I have.

Going to send the calipers off for a professional refurbishment as theses are keepers so worth the investment now. Will also need new tie rod ends as the current ones are seized into the hubs (hammering and WD-40 was ineffective all 10 times I tried) so will take them off with the hubs. Going to replace the ball joints and wishbone bushings too, seeing as it’s all apart and makes sense to refresh everything in one hit. Will also press out the bearings and hubs to freshen the carriers up and fit new bearings and hubs too, no point leaving those out the party.

So that’s all for now but I’m off work for quite a while now while I job hunt for a new career so while I’m not sat sending e-mails and making calls, I’ll be trying to sort Hayley out ready for summer. Summer 2019 that is, at this rate…

Moving over to Flickr, sorry for the broken picture links!

Offline doylebros

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #61 on: December 29, 2017, 06:53:51 PM »
The title "It Runs" is gift to the mind, from the body's hard labour, so enjoy.

It's important to understand many people start similar projects and fail because of external distractions or more demanding commitments for their monies I t takes to for fill such a build.

If you document its challenges and rewards (detailed enough) it will be a journey you can look back on for both pleasure and confidence, when your moral mind fiber is low and the body weakens.

I find when I look at projects such as this, the builder, neglects the key areas they know little about, for no apparent reason, which greatly restricts the overall build quality, eg mechanically minded neglect bodywork and Bodyworkers neglect all other areas. So it you want it to be a Show and Go project, neglect none of the areas you may not find a pleasure to undertake.

Oh and good luck on the career change. :happy2:


Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #62 on: December 29, 2017, 08:10:17 PM »
Very interesting point you make about neglecting areas and I find myself currently neglecting the body work in favour of mechanical issues but I fully intend to give it some attention in the form of a body shop.

I'm not scared to admit I can't do it to the right standard that this car deserve so no shame in band my it over, when the time (and bank balance) is right.

Moving over to Flickr, sorry for the broken picture links!

Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #63 on: January 03, 2018, 06:30:05 PM »
Couple of pictures of the G60 calipers just before I sent them off for a professional refurbishment:




Originally had these for Harriet to cope with her VR6 engine but shortly after found the RS2 ones so these were spare. Hoping they come back within a few weeks so I can get the car rolling and outside into the sunshine, mainly as I need to sweep my garage floor.

Due to a tight budget lately, I’ve run out of spare cash so no new parts can be sourced for a few weeks, so decided to clean up and beautify some more engine bits. Started with the small inner cam cover:




Alternator mounting hardware was also up for a refresh:




Forgot to get a close one of them painted as I left them drying a bit while I tackled the pumps. Got the pulley off the water pump, took it right back and re-painted it:



Will be getting the new water pump as well as a thermostat replacement as soon as I can afford to, I would of re-used the original one but it’s full of corrosion from the head so not worth it. Here’s everything that’s been painted so far:



Got the new power steering bracket painted up too, but this is a work in progress shot as I still need to flip everything and do the other side. Got the other mounts apart from the actual pump, they are going to be a bit trickier to clean up but I’ll find a way. Also have the issue that the Mk3 Golf setup on a 1.8 8v engine isn’t quite in line. I didn’t take a picture but when the PAS pump is mounted up it sits about 1 belt width out towards the chassis leg which is a bit of an issue. I knew you needed some Mk3 brackets but later found the forum post (over on Club GTI) that I read before which says you also need the alternator and mounts, plus different crank pulleys…

Had a bit of a think and so far, from what I can see, a Mk2 Golf GTD PAS pulley is offset slight from the mounting face so thinking of getting one and seeing if mounting it solves my issue as I want to retain the Mk2 Golf alternator now mainly for cost but also because I just painted mine before I discovered the above:



Plus, it means no wasted belts and reduces the amount of parts I’ve bought that don’t work with this setup. Worse case I’ll buy replacement Mk2 Golf PAS brackets and hardware and just re-build what was there. Another issue I ran into is that on the bottom of the cast iron block there are two tabs with threads which the bolts for the PAS pump bracket bolt into. One of mine (the outer one) is broken off so only one bolt holds it up! This means, as far as I’m concerned, that this block is on a limited life until the other engine gets built up, then all the ancillaries will get transferred over to the new block and head as well as any lessons learned from this current gas flowed head.

Essentially this is an R&D build right now to see what works and what needs further improvements. Mainly suspect that a 272-degree camshaft will be a bit lumpy at idle and top-end-focused for road use so may source a 268-degree camshaft for the next build. I toyed with a 1.8T swap which may come much later but right now, as the car is still in the “potentially sell again” area of priorities, keeping it close to original is my main goal for resale value.

That being said, my girlfriend keeps telling me we should keep it for the long term and go to town on it… She’s currently working on her Seat Arosa, retrimming all the interior and learning how to do all the mechanicals. We’ve re-done the brakes all round, lowered on Koni dampers and H&R springs, rear anti-roll bar and a load of service work. I’ll see about adding some pictures of her car once we get the new wheels this week and it’s a bit more sorted and once the new seats are in and interior trimming finished some of her work inside. She’s already done an upholstering course using some old Beetle seats and she wants to carry it on further for fun so could make for some interesting updates too.

Moving over to Flickr, sorry for the broken picture links!

Offline doylebros

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #64 on: January 03, 2018, 07:29:12 PM »
Evening. How could you ask for more, you've got a project educating the mind and soul, it's that type of project on a limited budget which bring about life skills you didn't know you had or could develop, so good on you.

Previously when I've had small items like you've been refurbishing, I've used my local wheel refurbishing chap, to do a bulk set of my bits when he's quiet for cash, and his price has been £25 for the items, so may be worth asking someone in your area.

Loved the thought of your girlfriend doing the vehicle interior course, then getting stuck into her own project 10/10 to her.
Collectively after a few projects you'll make an interesting team, it's that experience which become priceless if your funds are limited.

I still find doing the work with enjoyment being top of the list, rather an a means to make money, will end up producing plenty laughs, giggles and great memories for you both.
Oh and just remember any form of hard labour is better than watching that television!


Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #65 on: January 17, 2018, 11:38:27 AM »
Made a start on preparing the power steering brackets:



They’re better looking now, need to get a picture of them built up ready to fit. Also ordered a new water pump, G60 thermostat which operates a lower temperatures, flange and an adjuster bolt for the PAS setup:



Came with a free water bottle. Nice! Something else arrived too…





The look alright, but I have messaged the refurbishment shop with some feedback as the finish isn’t that good to be honest, especially given the price paid for them. I’ve achieved better finishes with a rattle can in the workshop…

Next job is to sort out the brake lines up front, managed to source a 9-inch servo and 22.2mm master cylinder from a Corrado for a nice price so will re-condition that up and fit with the new copper brake lines to give ultimate confidence in the braking system. Also thinking of going for a wide track using Mk3 Golf 4-stud parts to keep the 4x100 stud pattern but increasing the track width by 20mm. Will use spacers behind the stub axles out back to achieve a similar widening.

Moving over to Flickr, sorry for the broken picture links!

Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #66 on: January 20, 2018, 03:12:41 PM »
Got the GTD pulley:



Worked out perfectly, almost… First thing that didn’t go to plan is the pulley mounting face of the pumps. The Mk3 one sits in the opposite was to a Mk2 one, so even with the offset this pulley still sat too far over. So, I used Mk3 Golf brackets with the Mk2 pump but has to grind a small amount off the pump in order for the pump to clear it and spin freely. Also had to double washer the bolts as they’re slightly too long.



Tensioned up lovely, the Mk3 Golf setup is miles better than the Mk2 one! Finally had the car running and up to temperature today but she smoked badly! My CO2 mixture is well off so needs a full tune up and sorting when I’m finished flushing the various systems through. One round of 20w-50 oil is through, got another one to do before dropping it and the filter and then putting the 10w-40 in which will stay. Got Holts cooling system flush to use (a 2 part treatment) so will report on that when complete.

Moving over to Flickr, sorry for the broken picture links!

Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #67 on: February 08, 2018, 07:05:06 PM »
Got the pump all fitted up and the engine running nicely:



Finished running the flushes through the various systems, now time to address a few other jobs I want to get done. Firstly I noticed the cooling fan seemed to struggle to get going but a spray of WD-40 seemed to fix that. Decided to take it off to look into it and snapped the threads for the bolts on it so it's being replaced for a new item.

Also made a start on overhauling the entire brake system starting with the servo, master cylinder and lines. Removed the stock items:



Has some difficulty with the unions, so decided to just cut the lines with the grinder and use a socket to remove them, was much easier and saved destroying the lines to the rear for now:



Forgot to get some snaps of the space left behind. All I'll say is I should of done it when the head was off as I needed to remove the entire intake system, including the throttle body, in order to get the servo out. Refurbishing my 9" replacement unit which, being from a 16v Corrado, has the ABS sensor on it so that combined with the front hubs also being ABS ready means an ABS retro-fit is possible sometime in the future should I desire.

Here's the new pre-bent front lines:



Got these off eBay, the seller does them to order pretty much and they're spot on! While on eBay I started ordering a few other bits...

Mk3 Golf 4-stud wishbones, track rods and ends, driveshafts and the other required hardware to fit them along with the brake discs and pads. The hope is everything arrives by the weekend so I can get the car at least able to be rolled out the garage if needs be. Still need to order a master cylinder as the one that came with the servo is too long and has the ports in the wrong position.

Driveshafts arrived within 24 hours which was awesome:



Will get some more pictures and update on progress over the weekend.

Moving over to Flickr, sorry for the broken picture links!