It Begins: The S3 1.8T into my '85 Mk2 GTI

[tommymac]

from http://www.conrod.co.uk/20v4.html

i used a throttle cable from a 1600 or 1300 too, i got it through VW When i change to 02a i will be using the SEAT set up too.

NEW GEARBOX

After I got the engine running my boost level was peaking around 7psi, not a lot but enough to make the clutch slip on the standard Mk2 box. The original box is known as a 02O, has a rod gear shift arrangement and a tiny clutch! I had no choice but to fit a later Golf mk3 02A box, I could have also used a 02M 6 speed unit but these tend to be quite expensive. The problems with using a later box are it uses a cable gear shift and the clutch is hydraulic, not cable.

You have a choice for operating the clutch - you can either source a manual setup (more on that in a moment) or fit the hydraulic setup from the donor car. You will need the clutch pedal, master cylinder, slave cylinder and a pipe between them. I was put off doing this as the bulkhead requires a little modification to make the pedal assembly fit. I decided to use the manual kit. Around 1998-1999 the Seat Ibiza 2.0 16v was fitted with a 02A box with a cable operated clutch. The parts you need are pushrod assembly, cable support bracket and a new cable. The Seat was fitted with an auto adjusting cable which proved to be a very tight fit in the Golf, I used a cable from a Mk2 Golf 1.3 which is a manual adjust type. The pushrod assembly bolts in the same position as the slave cylinder and the bracket bolts to the gearbox mounting. Simple!

[GOLFBALLS]

Great stuff mac daddy!

I think i will get my std mk2 throttle cable professionally extended. There is a mob in perth who can do it. Although most use that 1600/1300 carbie throttle cable, most also use the 1.8t with the throttle body on the drivers side unlike the AMK!

Cheers

[tommymac]

swap the mani to an AGU you know they flow well! fair enough the 1300 will fit the psng side too there is some length to it.!

[Greg Roles]

Just wanted to say how majorily impressive this thread is. As a MK V type, and diesel to boot, I don't really pay a lot of attention to some of the other sections and only came across this thread today . To have spent all that time and effort AND without any prior knowledge, well, you should be proud of what you've done. Good on you!

You make me feel like an amateur in the mod game!

[Golf Loon]

Just on the throttle cable mate, if you get a motorbike shop to do it, they will do it cheap and easy.
I`d get 2 made as then you have a spare one for if it breaks in the middle of nowhere.

[GOLFBALLS]

Cool that makes good sense!

A few uptades from today:
Got the 'sprintercooler' and radiator fitted up today! Its all pretty snug but it fits nice and there is enough room (just) for the pipes & hoses. I did have to do a little bit of chopping to the slam panel though!! The only issue is that the drivers side high beam light fouls against the intercooler so the grille wont fit unless i remove that light! Dang.
I'll just do away with that light for now until I can move the rhs end of the rad/i.c back a bit to make some room.

Also, I spoke to the wheel polisher today about the airleak and he said he never split the rims, just removed the bolts (a couple of which he mangled!), so its not a re-sealing issue. Its most likely that the valves are leaking at the base due to the lips being slightly thinner from the light skim. He will sort them out tomorrow.

It is nice to see the Golf almost looking like a car again.

Pics coming soon (i forgot to take up the camera today!)

Cheers

[tommymac]

goos shiat, nationals?

[GOLFBALLS]

goos shiat, nationals?

ummm.. goos??. LOL!

Nationals... when?

[geoff_gti]

I'd say he meant good shi*t, ya goose lol!

Great to see you've nearly got it done Wade, top effort. I reckon your mechanical knowledge will be a damnsite better that most people's after this build!

As for the Nats - check events area, weekend of May 22/23 I think.
Drive to SA for your training course on the 16th weekend, then stay over east for the Nats the weekend after! Easy!

[DubSteve]

Good stuff bro starting to sound insane