Few Problems, Help please.

[AndyPt]

Hi Guys, was hoping to have this new engine running today, but I've ran into a few problems, any help would be greatly appreciated.
First of all, it's a 2l bottom end from a mk3 golf, the head is from a mk1 golf gti.
First problem is the bloody K&N Filter I bought, It won't fit, few pictures below to show what's going on.









Is there anyway to get past this, or am I looking at buying another smaller filter?

Next problem is I got a mk3 golf gti rocker cover, all nicely polished etc, but it's stopping the 'thing' that the fuel lines go into from sitting snug and it won't bolt down properly, any ideas what to do, picture below.



...Next Problem, on the 2l block there appears to be another coolant sized pipe on the front, what do I do with this, what plumbs into it, from where to where? Photo Below.



It's the lower of the two.

Last but not least, this block has an oil cooler on it, which my previous one did not have, I've got a pipe for what appears to be the inlet, but where does the outlet pipe go to?



Not a very good picture, but hopefully you will get the idea.

Thanks for having a look.

[mark1gls]

With my oil cooler there is a hose coming up from the rubber water hose which goes from the bottom oulet of the water pump to the metal water pipe (you can see this hose with out the extra pipe on in your bottom photo, just above the bottom radiator hose) so you might need to get a different water hose. I think the part number is 068121058C but don't quote me on that code as its for a Mk1 Golf DX engine!

The other outlet near the dissy looks like for the warmup regulator on the injection fuel system, but not sure?

This is what happens on my Mk1 Golf Gti, DX engine.

[Risocco]

Problem 1 - The 2l block is physically taller, so your carb is closer to the bonnet. Smaller filter time. Or twin carbs if you don't like money.

Problem 2 - You can get longer head studs. Have you changed the gasket to a MK3 Golf one already? If not do so, the kit I bought came with crazy long studs that would solve your problem. Of course, if your running a single carb with a mechanical/low pressure pump, you don't actually need that reservoir.

Problem 3 - Its part of the MK3 Golf oil breather system. TSR do a kit to blank it off at the block.

Problem 4 - Personally, I would do away with the factory oil cooler and get a Mocal style one. Much more reliable. What I did on mine, not cheap but far more safe and looks better too.

[AndyPt]

Problem 1 - The 2l block is physically taller, so your carb is closer to the bonnet. Smaller filter time. Or twin carbs if you don't like money.

Problem 2 - You can get longer head studs. Have you changed the gasket to a MK3 Golf one already? If not do so, the kit I bought came with crazy long studs that would solve your problem. Of course, if your running a single carb with a mechanical/low pressure pump, you don't actually need that reservoir.

Problem 3 - Its part of the MK3 Golf oil breather system. TSR do a kit to blank it off at the block.

Problem 4 - Personally, I would do away with the factory oil cooler and get a Mocal style one. Much more reliable. What I did on mine, not cheap but far more safe and looks better too.

Eventually got the Air filter to fit! Just took a bit of fiddling with.
Yup I used the longer head studs, didn't think of that, thanks!
The TSR Kit is something like £60, is it really necessary to block it off, or can I just incorporate it into the breather system I'm going to make for this engine?
And I sourced the right pipe for the oil cooler, so that's sorted now too!

[AndyPt]

Right I have another problem, any help would be greatly appreciated, quite worred that I've messed this up now.

So, I've connected all the coolant pipes up, wired up the whole engine, everything is ready to go, and as i start filling up the coolant I hear the water gushing out of the engine somewhere, I looked around and found that it was coming from underneath the carburettor manifold.
Have I somehow managed to plumb it all in wrong, and now have water and coolant in the engine, or is there something under the manifold that needs tightened or something of the sort?

Cheers.

[ianaudia4]

I sounds like the core plugs are goosed, cheap to buy but a git to get access!

[AndyPt]

Core Plugs? Sorry not heard of them. Thanks though!

[ianaudia4]

The core plugs are on the back of the engine as you are looking at it, here is a definition:

http://www.google.co.uk/url?sa=t&rct=j& ... si0GZG-JOg

And a picture:

http://www.google.co.uk/imgres?q=vw+cor ... s:40,i:199

[MikeH]

Core plugs are down near the driveshafts. You didn't just forget to put the coolant channel O ring in the inlet manifold, did you?

shove a clean rag in the breather on the front of the block, as a temporary measure, but don't shove it so far in that it gets caught up in the intermediate shaft. Look for the breather pipes and 'flying saucer' breather canister from a MK3, or make your own up, or fit a catch tank.

[AndyPt]

Core plugs are down near the driveshafts. You didn't just forget to put the coolant channel O ring in the inlet manifold, did you?

shove a clean rag in the breather on the front of the block, as a temporary measure, but don't shove it so far in that it gets caught up in the intermediate shaft. Look for the breather pipes and 'flying saucer' breather canister from a MK3, or make your own up, or fit a catch tank.

It turns out I really was that stupid and forgot about the coolant O ring, thanks though. Now I've got to fight with the inlet manifold while the engine is still in the car - Fun times ahead!

Okay thanks, I'll look into those for the breather.