Exhausted !

I spent a while trying to find a decent exhaust, I didnt want a stainless system just yet as I want to see how loud it is then get a custom one fabbed up. I thought I would stick with the Golf system as it was already suited to the engine but obviously I had to really modify the shape to get it all to fit.















I found a nice Ashley 2.5 inch one from a MK2 GTI. It didn't take too much effort to change all the bends and I added a rubber hanger to allow the box to move a bit. Its quite short and its a straight through box so I think it will be quite loud. I managed to get most of that sorted in one day, then I moved on to mounting the fuel pump.






I added new rubber mounts and new filter, the mounting bars are just bent metal. Its a Golf MK2 8V Digifant fuel pump, with just the swirl pot. No accumulator like the 16V but this is plenty enough to stop fuel surge.













I quickly added a return spring to the accelerator pedal fashioned out of a spring from some garden loppers, just the job and gives the pedal a good feel.

I sent my ECU away to get the immobiliser deleted which hopefully will make the wiring a lot easier.
Unfortunately I forgot to take the OBD port from the Golf so I wont be able to talk to the ECU.

Recently started the wiring loom from the Golf engine, and started to separate and identify all the wires I need and don't need. I must admit I wasn't looking forward to this part but I did enjoy it after a while. I am currently still on the wiring and struggling to trigger the fuel pump relay.
Close but not quite ready to hear that exhaust note.

Diesel Out !

The time came to remove the KY 1.7 N/A Diesel which was a shame really as it was a reconditioned unit with only 47k on it but I couldn't live with this sort of power or lack of it.

The engine flew out, it was really easy to drop, no problems and lowered it onto my professional engine moving device (skateboard) I made a note of where a lot of parts went and made sure I didn't damage anything.

I tied all the electrics neatly out the way and completely stripped the engine bay so I could patch a few holes and respray it all.

I rubbed the bay down to bare metal and sprayed it all in primer for now but I'm going to spray it in the main body colour before I start re-fitting the engine and components.

It did have a diesel battery tray which I removed because I want to tuck the battery away behind the offside light cluster, I might put the AGG ECU in there as well away from most of the heat and moisture.

Stripped off exhaust and inlet manifolds, next I need to fit new water pump, cam belt and tensioner various gaskets seal including crankshaft seal.

I'm only doing a light rebuild on this motor as I'm happy with how it was running when I removed it from the golf, but I still need to replace every component I can without taking the head off.

The sump and oil pump pick-up will be swapped for the diesel and the diesel engine mounts will be fitted.

I'm still hunting for a non air con model alternator mounting bracket so it wont poke above the engine lid and I can use a serpentine belt.
I could actually use the old diesel alternator with a bracket from an early golf but tensioning it might be a problem.
I haven't got this far yet so I will see what I can come up with.