'89 Golf Mk2 TDi Build Thread

Discussion in 'Mk2' started by DN5, Apr 11, 2016.

  1. DN5

    DN5 Paid Member Paid Member

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    Excellent, thank you very much Rubjonny, it's loads easier to get my mind around it once things are confirmed :)
    I'm going to whip out the mk3 engine loom again and decide what's to keep from both regarding brake fluid reservoir, Coolant level etc. No need for both sets there and I'm thinking mk3 gear in the bay so probably that route.
    Had the interior loom out today and that's spot on, just needs the fuel pump wiring removing I think. Everything else OK. I shot myself in the foot really as it's a ce1 to ce2 swap also I just chopped the knackered old ce1 into bits so have no 'template' to go off but I think I'll be OK now with the help :) Cheers!
     
  2. DN5

    DN5 Paid Member Paid Member

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    Ta-Daa
    20160728_212646_zpsgh0m1b9o.jpg

    Totally stripped back, checked, all the trash removed leaving just the necessary there. Hopefully to be hidden down the chassis legs :)
     
    Last edited: Oct 3, 2017
  3. DN5

    DN5 Paid Member Paid Member

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    Last edited: Oct 3, 2017
  4. DN5

    DN5 Paid Member Paid Member

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    So I've got a guy coming today to have a look at the welding work I want doing and thought best to bash out the firewall for the clutch mc before he gets here. Un drilled as yet but a couple photos to show how it looks.
    20160910_100437_zpskruzzaxw.jpg

    20160910_100425_zpsxibkxfox.jpg

    Once drilled and installed I'll update.
    Now to get my head around how I'm going to install the kit for dbw. It's pretty tight up in the pedal box so going to make a bracket of some sort for it to sit in. Thanks.
     
    Last edited: Oct 4, 2017
  5. Tomhoms1992 New Member

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    How do you plan on sorting the rusty scuttle? Is it a case of chopping it out if rotten and welding a donor one? Only ask because I'm new to MK2 scene and every one I've seen so far have had badly contaminated scuttles
     
  6. DN5

    DN5 Paid Member Paid Member

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    By 'Scuttle' you mean around the windscreen right? I have sourced a new replacement and I'll have this welded in along with a few other replacement panels next week before it goes for paint. If though you were meaning the firewall you see in my last picture, I'm thinking that's going to be blasted, rust treated and then painted. The mk2 scene is fun :)
     
  7. DN5

    DN5 Paid Member Paid Member

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    A quick update...got round to finishing the heater issues. Previously I refurbished the flaps and today I replaced the fuse in the resistor pack. So now instead of 'OFF' and '3' being my blower speed choices, I should be back to normal :) and get warm air!!
    20161008_170508_zpssycmna58.jpg
     
    Last edited: Oct 4, 2017
  8. DN5

    DN5 Paid Member Paid Member

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    After tidying up the mk3 front crossmember and making the hockey puck front mount (dead easy to do btw)
    It's dawned on me that the mk3 won't fit...AT ALL!!
    So just ordered a passat B4 item.
    Needs tarting up so gonna get it powder coated with the rear beam and a few other bits. Just need the car back at my garage now so I can crack on. Excited for its return!
     
  9. rubjonny

    rubjonny Administrator Staff Member Admin

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    yarp the mk3 front carrier is no use its the corrado vr6, or larger engined passat b4 or toledo one you want
     
  10. DN5

    DN5 Paid Member Paid Member

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    I managed to get one from a passat tdi so if I can use the hockey puck front mount I'll be pleased.
     
  11. DN5

    DN5 Paid Member Paid Member

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    Had a go at the timing belt a few weeks back and wasn't happy with how the pulleys seemed to align afterwards. Bought the camshaft Lock and the injection pump locking pin and had another look at how it aligned today.
    Spun the engine to TDC on the crank, then had to wiggle just a fraction to get the cam lock in place
    20161212_132955_zpswldyhbo7.jpg

    The injection pin literally just fell into place
    20161212_133009_zpscj6u3lba.jpg

    And without any playing, this is where the TDC mark was
    20161212_133430_zps9tidnfwp.jpg

    Happy with that :)
     
    Last edited: Oct 4, 2017
  12. DN5

    DN5 Paid Member Paid Member

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    Taken delivery of 4 of these beauts [:D]
    20161213_163732_zps3yo6ekqm.jpg

    Need a test fit to determine stretched or standard tyres though.
     
    Last edited: Oct 3, 2017
  13. DN5

    DN5 Paid Member Paid Member

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    IMG_4411_zpsxdgof4hn.jpg

    IMG_4412_zpswbiep94j.jpg
     
    Last edited: Oct 3, 2017
  14. DN5

    DN5 Paid Member Paid Member

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    Just looking at the vacuum routing today and playing with where to locate the n75 and I came across this.
    20170401_121303_zpspeh0ounj_edit_1491045547348_zpsn6l8lwdb.jpg

    I have no notes or photos showing what connects here.

    Can anyone point me in the right direction :)
     
    Last edited: Oct 3, 2017
  15. rubjonny

    rubjonny Administrator Staff Member Admin

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    is it not for the ECU?
     
  16. DN5

    DN5 Paid Member Paid Member

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    Now THAT I did overlook!
    Cheers
     
    Last edited: Oct 3, 2017
  17. DN5

    DN5 Paid Member Paid Member

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    Fitted a new mk4 alternator that a friend had spare. Thought it'd be a worth while upgrade as it was free!
    New Alt -
    20170709_214559_zpsenbgdv7u.jpg

    And the plug spliced and soldered into the existing mk3 loom and wrapped -
    20170709_214611_zpsqc2vovhp.jpg

    Also wanted rid of the breather on the block. Main reason was because the crappy weak pipe annoys me and secondly it looks tidier. I plated this over with a genuine VAG blanking plate -
    20170709_214627_zpseluhpdmd.jpg

    Then that left the empty inlet on the PCV cap to sort -
    20170610_164728_zpseje2fq2l.jpg

    Found one from an ALH that had just the 1 outlet. Loads tidier in my opinion. And no more cracking pipes and oil leaking from it -
    20170709_214643_zpsun7qcna3.jpg

    That's all for now.
     
    Last edited: Oct 3, 2017
  18. DN5

    DN5 Paid Member Paid Member

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    Anyone else having trouble with photobucket?
     
  19. dsj20v Forum Member

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    Yeah they are robbing bast**** they've changed policy and basically holding people to ransom over your own pics, wanting something like 400 per year to let you have them back
     
  20. DN5

    DN5 Paid Member Paid Member

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    They won't be getting 400 off of me! I'll look at opening a new account with someone else and swap all my photo links. What a ball ache!
     

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