My Ongoing Project/Daily Driver

[bengould]

Finally got some work done on the conversion today.

Was donated a spare engine mount and treefingers kindly pointed me in the right direction of how to modify the mount to fit to the 20v engine. Ended up with this...



Modified the alternator bracket to get rid of air con compressor and power steering pump mounts. Got a smaller belt to run just an alternator. And a manual cam belt tensioner.



Stripped every cable, wire, hose etc from the old engine and removed all the excess from the old engine loom.



Still halfway through here. But you get the idea.

Once the engine was out. Removed the gearbox and flywheel to fit to the 20v engine. Bolted it all up along with my newly butchered engine mount. And dropped it in.



Fitted a slightly larger than expected Mercedes sprinter intercooler. I probably should have measured one of these before I got this one. But it was cheap. And it does fit. Just.



The radiator will go between this and the engine, but am going to need a slim fan.

I have a fuel filter and bosch 044 fuel pump that is going to be fitted to the inner wing on the drivers side of the car.

Have still got to plug the loom into the fuse box and ecu, connect clutch cable and speedo drive, figure out where my boost hoses will go, bolt up driveshafts and get the downpipe to meet up with my exhaust. Probably a few other jobs I've forgotten to mention, but have made a decent amount of progress at last.

Ben.

[bengould]

Was down on Sunday and got a load more done. Was a bit poor with the camera though so only a couple of pics.

Got the Front and rear engine mounts in and bolted up.

Driveshafts back in.

Loom all in the car now, just needs plugging into the dash for the rev counter and temp gauge. and tidying up a bit behind the dashboard.

Starter and alternator nearly all wired up





Just need to figure out which of the two pins in the alternator plug my one blue wire goes on to.

Fuel filter and Pump are now in the car roughly where they need to be, waiting for a bracket for the pump and inlet/outlet adapters to turn up so I can finish plumbing it all in.

Most of the pipework for the turbo>intercooler>inlet manifold is now measured and ordered.
And all the coolant hoses are now plumbed in.

Exhaust is going to be the only major headache but I'll get that worked out last.

That's all for now.

[treefingers]

good work! you'll have it running real soon at this rate..

my wiring guy told me it's pin 2 on the alternator plug, i've gotta connect mine tomorrow.

[bengould]

I hope so, The exhaust is going to be the biggest hurdle now I think.

Just been speaking to a guy on Scottish VAG about alternator wiring. It's the one nearest the front of the car at the rounded edge of the plug.

Was your loom done by a guy in Dunfermline by any chance? Think it had just arrived when I went to pick mine up from him. I kind of recognise the box.
If so did he e-mail you a list of bits to buy for fitting? He was supposed to send me something but for some reason it isn't getting through.

Ben

[bengould]

No pics yet, and not a lot of progress.
The install is now done. Exhaust connected, managed to use the original downpipe welded to the turbo end of the 20v one. Its a bit close to the steering rack, but it will do until I can get it over to the guys that did the rest of my system and I'll get them to make me a stainless one up.
All the inlet pipes are plumbed in and I've even managed to turn the key for the first time.

And that's where it stops. Doesn't want to run at all.
Checked for fuel at pump and injector rail, yep.
Checked all the loom connectors are on properly, yep.
Checked for fault codes, just abs and charcoal canister missing, both can be safely ignored and won't cause any issues.
New crank sensor as this is apparently one of few things that will stop it running. Still nothing.

Picked up a coil pack controller (n122) today and have bench tested it as ok, need to fit that next time I'm over there and see if that helps.

As far as I can tell it isn't sparking, but I can't figure out why. It is very rare for an agu coil pack to fail, let alone all four so I doubt it is that, but will be testing those with the multimeter next time I'm over.

Other than that, I'm stumped.
Will probably end up having to check every connector on the loom has continuity back to the ecu. But since I'm not getting any fault codes, I'm not sure it will be much help.

Ben

[bengould]

IT'S ALIVE...

Turned out to be a pretty simple wiring error. The ecu ignition feed was being turned off when cranking the engine, swapped the feed to a different pin on the fuse box and it went straight away.

What an improvement too. Still a standard 150bhp but the power comes in nice and smooth, hardly any turbo lag and even with my mega tall 5th gear it takes off pretty well. Was a bit wet out tonight so 1st and 2nd were pretty much useless, 3rd was interesting, 4th and 5th was great. Can't wait for a bit dry weather.

Need to do a bit of tidying up in the engine bay and interior, and I will be getting a stainless downpipe made up as soon as I can get booked in with the exhaust guy.

Other than that it's about done.

For now. .

Pics to follow at some point and maybe a short video one day.

Ben.

[treefingers]

that's awesome you got it running. good work! i had a big head scratcher with key turn issues.. feels so good when you find the problem eh! well you beat me anyway.. i've only driven my 20v about a meter across the workshop floor!

[bengould]

Feels great. So happy to finally have it running. It's going in first thing tomorrow for a custom stainless downpipe to replace my butchered standard 8v one.

Ben.

[bengould]

And after all that hard work.....



I'm beginning to think me and Scirocco's just aren't meant to be.

On the way to volksfling yesterday and got a bit of a surprise coming off the roundabout at Abingdon services when the woman in the outside lane of the roundabout decided she wanted to go right instead of left and proceeded to do so via my passenger door.

Not happy.

Waiting till I get home to try and open the door so I can have a better look at the damage.

Fortunately both parties involved were OK and both cars were drivable.

Anyone selling a good solid mk2?
Engine and running gear not an issue as all my stuff will be transferred over but am now on the lookout for rocco number 3.

Ben. .

[scirockirb]

Unbelievable!! So sorry to see this... Been following this thread waiting for more pics, but not like that! Hope yo sort it fella.

[Chris6969]

That is absolutely brutal man ! Like the above, been following and waiting for more pics, but Quote "Not like this, not like this". Hopefully something good will come your way. You looking for a project mk2 again or ready to go.

[Risocco]

So sorry to see this mate. After all that work too.

[bengould]

I've got lots more pics just never got round to uploading them, was having too much fun driving it.

Honestly not sure where I want to go from here. Depends on the damage, but can't really tell while I'm at volksfling this weekend. I don't want to force the door open in case I can't close it again.
If the sill is good and I can just get away with a new door and respray I'll probably just do that.
If the sill and floor is bent I think unfortunately I'll just take all the good bits off and get rid of it. While I'm aware that it can be fixed and would probably be fine, I don't think I'd ever really trust such a structural repair.

Ben.

[treefingers]

Absolutely gutting! judging by the window glass being ok and the sill looking pretty straight hopefully its just a door wing and some beating/filler/paint

[bengould]

Been out today and managed to open the passenger door.
Wasn't as difficult as I'd expected it to be, the rod had come off the outer handle so just pulled the inside one and it opened.

Looks like the door and outer sill has taken most of the impact



The sill on the inside of the car looks mostly straight, but the bit that joins to the b-pillar on the inside has a crease in





and the bottom of the door shut on the b-pillar has a small crease in.



Difficult to see in the picture but is just visible at the bottom of the finger marks where I've wiped the dirt off. lol.

Still not terminal, but a little worse than I had wanted. Was kind of hoping I could just swap the door and that would do.

Ben.