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Old 07-10-2019, 09:02 PM   #2421
eurocars
5/17/15 - Never forget
 
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It’s already plumbed and working so i might as well keep it. Can’t see any of it anyway
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Old 07-11-2019, 10:31 AM   #2422
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That's extra weight though
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Old 07-11-2019, 11:28 AM   #2423
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Pump doesn’t even weigh 3 lbs, tubing under 2 lbs. Probably actually less weight than the mechanical one off the side of the head, plus it looks better (which is what i really care about anyway)
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Old 07-31-2019, 10:33 AM   #2424
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Spare transmission case is at the powdercoaters, should be back by the end of this week. Peloquin LSD added to the mix as well. Testing engine wiring today

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Old 08-05-2019, 01:45 PM   #2425
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Not getting the gears cryo-treated and ceramic coated for low friction?

(makes it easier for your power to get through the transmission)
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Old 08-05-2019, 01:57 PM   #2426
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Just trying to get it together at this point. Don't think it would be a major improvement over what I already have
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Old 08-09-2019, 07:56 PM   #2427
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Transmission is back from powdercoating. Need to order a few more bearings but then it’s ready for assembly

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Old 08-09-2019, 09:47 PM   #2428
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Such great attention to detail, what a great project.
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Old 08-23-2019, 02:45 PM   #2429
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New transmission is back together, all new bearings and seals. I wish the color wasn’t so brown, but it’s the closest one my powdercoater could find to match the duplicolor cast iron grey that i painted the block with



Input shaft brace sealed from the inside AND outside (they are notorious for leaks)




My very professional preload measuring setup

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Old 08-25-2019, 06:30 PM   #2430
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Went live today with the battery, no smoke and no fires. Was a little nervous after lots of wiring work over 2 years. No engine fault codes either.

Only issues i noted so far is that somehow all of the central conv. coding reverted back to factory, the brake switch turns off the lights instead of turning them on (not sure if coding or wiring since i went with a MK4 switch), the coolant level sensor is beeping even though i wired it so it should be off, and even though my headliner was in perfect condition when i parked the car i noticed today that the entire center section has separated. Only noticed it when the wife went to put the battery cables on and hit it with her head.

Next week I’ll swap in the built trans, wrap the rest of the engine harness and start installing the rest of the drivetrain.

To do:

Fill all fluids
Double check all engine hardware torque
Loom rear section of engine harness
Swap transmissions
Bolt up axles
Route PCV hoses/figure out catch can solution
Put new fuel in tank

After that it’s driving. Not sure if the 70A alternator is enough, but we’ll find out
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Old 08-26-2019, 09:21 AM   #2431
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Quote:
Originally Posted by eurocars View Post
Went live today with the battery, no smoke and no fires. Was a little nervous after lots of wiring work over 2 years. No engine fault codes either.

Only issues i noted so far is that somehow all of the central conv. coding reverted back to factory, the brake switch turns off the lights instead of turning them on (not sure if coding or wiring since i went with a MK4 switch), the coolant level sensor is beeping even though i wired it so it should be off, and even though my headliner was in perfect condition when i parked the car i noticed today that the entire center section has separated. Only noticed it when the wife went to put the battery cables on and hit it with her head.

Next week Iíll swap in the built trans, wrap the rest of the engine harness and start installing the rest of the drivetrain.

To do:

Fill all fluids
Double check all engine hardware torque
Loom rear section of engine harness
Swap transmissions
Bolt up axles
Route PCV hoses/figure out catch can solution
Put new fuel in tank

After that itís driving. Not sure if the 70A alternator is enough, but weíll find out
That headliner issue is exactly what happened with my car
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Old 08-26-2019, 01:44 PM   #2432
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Quote:
Originally Posted by bon qui qui View Post
That headliner issue is exactly what happened with my car
My Golf, Passat and now GTI all have saggy headliners
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Old 08-26-2019, 02:16 PM   #2433
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Quote:
Originally Posted by eurocars View Post
My Golf, Passat and now GTI all have saggy headliners


Quote:
Originally Posted by bon qui qui View Post
That headliner issue is exactly what happened with my car


My mk5 also had this happen.

I scheduled an appointment with an interior team who is scheduled out till mid September. It will also cost a few hundred... which I think Iím okay with because the interior is immaculate except for the tent that suddenly appeared between last week and the week before. All was fine and then *boom* the material separated.

Now... alcantrara or just regular oem-like fabric?


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Old 08-26-2019, 02:31 PM   #2434
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I just took mine out
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Old 09-02-2019, 12:16 PM   #2435
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Had an issue with the gears locking up on the trans so I took it apart again to investigate. One of the brass pads on the steel fork was hitting the inside of the case, partially locking one of the gears and not allowing the two halves of the case to fully seat. Shaved the pad down with a file and everything rotates freely


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Old 09-08-2019, 05:53 PM   #2436
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Pulled the old trans to swap it out with the new one. Also pulled the oil pan because i saw some assembly lube on one corner of the pan. Evidently i didnít do the best job sealing it up. Fel-pro makes an oil pan gasket for the 1.8t that fit great after i modified it some. Also finally made myself a fuel pump controller extension harness since i was finishing up some for other people. The fuel pump controller now sits under the front passenger seat on the floor instead of under the rear bench seat





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Old 09-11-2019, 01:47 PM   #2437
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Finished making a new mounting bracket for my oil and coolant lines. The old mount i made wasnít great and i didnít want the lines rubbing on anything causing leaks. All lines are now wrapped and p-clipped. I added DEI to the mounting brackets and knock sensor connectors that i relocated to the rear of the block.

All hardware checks are done and all bolts marked once torqued. Engine is back in the bay, finishing the rest of the install later this week. Still need to loom the back section of the engine harness but i want to test drive it before itís all sealed up, so the back half is wrapped in black fabric tape



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Old 09-15-2019, 08:49 PM   #2438
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Body panels are back on. Only need oil cooler lines, axles and fluids before it’s driving


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Old 09-17-2019, 01:55 AM   #2439
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Very minimalist and clean

Did you ever consider plugging all the holes and smoothing out the engine bay?
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Old 09-17-2019, 10:28 AM   #2440
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Quote:
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Very minimalist and clean

Did you ever consider plugging all the holes and smoothing out the engine bay?
Eventually I will, i wanted to get it running first. My plan is to make/use MK3 style mounts so itís fully floating and smooth the bay
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Old 09-17-2019, 10:12 PM   #2441
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Finished making my oil cooler lines and picked up one of the TT axles locally (still need to source passenger side). It is about an inch longer than the GTI axle. Stock ones didn’t even come close to fitting

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Old 09-21-2019, 08:25 PM   #2442
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Added a battery cutoff switch for peace of mind. Mounted it under the drivers side trim panels.




Also whipped up a quick fuel pump harness to manually turn the pump on from a jump box. Figured the new engine probably wouldn’t like 4 year old gas. Have 15 gallons to pump out



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