MK1 Golf GTI 2.0 TFSI Edition 30 p12 (was 2008cc R1 bike carbs)
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Old Timer
1983 Lhasa Green MK1 Golf GTI
And as long as I removed all trace of the standard seat belts they would only test the harnesses, otherwise they would also need to check the original seat belts and mounting points.
A couple of hours later, I received a phone call to say 'Your car is ready to pick up'.
Phew, all passed with NO advisories either. Is there a better feeling than this?! I was very happy indeed!
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Old Timer
Matt
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Old Timer
I'm confident with wielding a spanner, but electrics are another thing altogether.
With that in mind I have started the daunting process of upgrading the 8v OEM+ engine, with 30 years it's junior, high tech, complicated TFSI engine!
Front engine stripped down and engine out..
It's actually a pleasure to strip down this 2008 Golf GTI Edition 30. The bolts in the engine bay were easy to access and remove and the engine dropped onto a pallet without much hassle. Probably took less time to get the complete engine out of this, than just taking an original exhaust manifold off a MK1 with those rusty arkward studs. (If you've removed a MK1 exhaust, you'll know what I mean).
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Old Timer
I'm pretty sure there is more wiring in just a MK5 door panel than there is in an entire MK1 Golf Firewall removed to allow removal of a uncut wiring loom.
It's been interesting process so far, just even figuring out what all these extra electrical parts do.
Canbus Module
ESP Sensor
Plus lots of other stuff including separate control modules for ABS, comfort module, xenon light sensors, etc etc.
The result THREE boxes full of wiring!!
This is going to keep me busy over Winter
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Old Timer
Exhaust mid section disconnected, front anti-roll bar removed and lower strut brace remove to allow the exhaust manifold to be removed.
Wiring in engine bay now being disconnected. Working on a MK1 engine bay, especially with the k-jet fuel injection already removed and boxed up, is very much a therapeutic effect and weirdly enjoyable!
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Old Timer
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Old Timer
Looks like I just found problem just in time
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Old Timer
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Old Timer
The big valve head has 41mm inlet and 36mm exhaust values, pretty much the biggest you can fit without having a Eurospec head which has 42mm inlet valves. Bigger than a TSR Pack 'D' as these came with 40.5mm and 35mm exhaust valves.
Compared to a standard head with 40mm inlet and 33mm exhaust valves. Not the best of images, but you get the idea.
Big valve head
Standard 1.8 GTI 8v cylinder head
Big valve head
Standard head
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Old Timer
Original engine mount spot welds drilled out.
And original engine mount removed and bracket put away some where safe (just in case I ever want to revert back to a OEM engine mount).
Unfortunately this uncovers more rust, so some additional prep work to this area will definitely be needed
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Old Timer
Engine bay bodywork looks great condition for a 34 year old car.
However on closer inspection, there was rust appearing around some of the brackets. So spot weld drill bit out and further investigation shows this.
All three spot welds removed.
The removed bracket looking this this.
Rust spot on panel
Hats off to everyone that have put in the effort to get their shells stripped and dipped. I assume dipping would remove and kill all rust in between any spot welded seams?
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Old Timer
Great quality and should cope well with the TFSI lump and gearbox.
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Old Timer
Below are pictures of the 02Q 6 speed cable change gearbox removed from the MK5 Golf GTI Edition 30 and about 45kg in weight alongside a 5 speed MK4 Golf GTI 02J approx 38kg.
Second picture is comparison of 020 8v gearbox with 90mm drive flanges and the 5 speed MK4 Golf GTI 02J with 112mm drive flanges.
If I remember I'll also weigh the 020 gearbox too.
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Old Timer
There is surprising very little wiring and only took 10 minutes to do.
This is first time since leaving the VW factory 34 years ago that the wiring has been disturbed.
Now compare the above to this, MK5 Golf GTI TFSI wiring
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Old Timer
Also found time to remove the brake bar and servo, with just a few small spots of rust to now deal with.
Next will be to remove the NOS genuine metal fuel lines. I managed to buy the very last UK available ones a while back, these run the full length of the car and were a pain to fit.
The original pipe will no longer be needed, as I'm planning to switch over to the MK5 TFSI fuel lines, so I can route these to the right hand side of the engine bay.
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Old Timer
I will be switching to a 02J based gearbox, so a G60 flywheel and VR6 clutch is needed, which is lighter than the original dual mass flywheel. The lightened G60 one being a further 35% lighter too!
As they say - less is more
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Old Timer
Surprising the Dual Mass flywheel is not that much difference in weight to a standard G60 flywheel at 9.68kg. The lightweight one in the picture below is 6.2kg
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Old Timer
If you are using a G60 flywheel and VR6 pressure plate, these are the bolts you need. VW Part number is N101 0101 01.
I can now finish installing the clutch and pressure plate.
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Old Timer
The 100mm shaft is on the left, 90mm on the right.
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Old Timer
There are too many online users to list.