Skip navigation

Golf FAQ

Post

Back to the top

Golf FAQ

Frequently Asked Questions
                             for
                      Water Cooled VWs
                      – Performance –
                        rec.autos.vw


Date:


Version:
     1 Feb 94 = Creation and copy from tech faqs.
     1 Mar 94 = First posting.
     1 Apr 94 = Conversion to MsWord for easier maintenance.
     1 May 94 = Solo I & II added. Books to read.
     1 Jun 94 = Relocating batteries, shock stiffness table,
lights, alignment
     15 Jun 94 =performance updates, Sound insolation.


Moderator:
   Jan Vandenbrande
   j… ug .eds.com
   j…@lipari.usc.edu (school address)


   See also the list of contributors at the end.


   Please feel free to submit any additional info.


————————————————————
—————
Copyright Notice © – 1994: All Rights Reserved
The  information contained here is collectively  copyrighted
by  the  authors.   The right to reproduce  this  is  hereby
given,  provided  it  is copied intact, with  the  copyright
notice  inclusive. However, the authors explicitly  prohibit
selling  this  document, any of its parts, or  any  document
which contains parts of this document.
————————————————————
—————


Index:
======
General issues        (Auto-X, )
Chemicals             (Rain-X, Lubricants)
Engine                (Power improvements)
Electrical            (Lights)
Transmission          ()
Brakes                ()
Tires/Rims/Suspension (shocks, tire widths & rim upgrades,
performance)
Body/Interior         ()
Miscellanea           ()


————————————————————
——–


                           GENERAL


Editor's  Foreword:  This  FAQ is geared  at  improving  the
performance of watercooled VWs based on the Golf Chassis (A1-
A3:  Golf  I/Rabbit,  Golf  II & III,  Sciroccos,  Corrados,
Jettas,  Vento,  Convertibles) using the   "1600  type"  and
larger  4  cylinder engine block and the  new  VR6  2.8/2.9l
engine. Because of this FAQ's origine, most improvements are
aimed  at the  US/Canadian market. The above cars also share
many  components with Dashers/Passats/Fox's (e.g., engines),
though  they differ in many other aspects such as suspension
and  exhaust  system. Some of these cars may  actually  have
more in common with Audis.


Performance  improvements  encompasses  a  wide   field   of
subjects,  most  commonly referred  to  in  the  context  of
increasing power and improving handling. This FAQ intends to
go  beyond  these  traditional meanings and include  changes
that  improve  upon the stock design. Performance  often  is
achieved  at  the  expence  of  something  else  often   not
mentioned  with  the  advertised  component  such  as   fuel
consumption,  harsher ride or noise.  This  FAQ  intends  to
reveal some of these as well.


One of the things to keep in mind is cost. In some cases the
improvements will costs as much as a new stock part from VW,
but  in other cases it costs more. Generally you will  never
recover  the cost of these improvements. Unlike real estate,
most  cars are not investments and therefore the reason  for
spending  money is for pure pleasure. For that  reason,  you
need to make a decision on whether it is worth it to you for
the  amount of time you want to keep the car. Also, it makes
little sense to buy the most expensive suspension system  if
your  engine  is about to blow. Fix the rest  first  perhaps
with better components.


Not  covered  in  this  FAQ  are  the  engines/fuel  systems
available  outside North America such as engines  less  than
1500 cc and carburetors/mono-throttle FI systems.


Another good thing to keep in mind is: "Speed costs money,
how fast can you afford to go?" [?]


Q:I  want to improve my driving performance? Where should  I
  start?
A:Yourself.  The  average  person  only  utilizes  a   small
  portion  of  their car's capabilities, and  often  do  not
  know  how  the  car  handles under  emergency  conditions.
  Taking  a  performance "Driving School" from  one  of  the
  local  clubs  (e.g. SCCA, ~1/2 day, inexpensive,  fun)  or
  from  a  performance driving school (e.g.  Bob  Bondurant,
  expensive,   fun)   is   probably   the   biggest   single
  improvement  you  can make. In every day  driving  it  may
  make the difference between an accident and avoiding one!


  The  next  question you need to ask yourself is *why*  you
  want  to  improve your car's performance. Do you  want  to
  impress your friends? Do you want to blow away other  cars
  on  the street? Do you want auto cross your car in a  club
  and  if so what type of racing do you want to do? Will you
  be  using  this car for your daily commute or will  it  be
  purely  used for off-track racing?  Depending on what  you
  want  to do, you may want to follow a very different  path
  to enhance performance.


  What  runs well on a track may not be acceptable or barely
  drivable  for a street car (clearance, noise,  hard  ride,
  rough idle, bent rims,  the law…). Additionally, if  you
  want to race in a club, cars are categorized depending  on
  their  power  and handling, and to what extent  they  have
  been  modified.   For example, it may be better  to  leave
  you  car  stock than to make certain mods (e.g., different
  rims)  that  will  put  you at  the  low  end  of  another
  category  (e.g.,  Street  Prepared)  and  be  totally  out
  classed  by  all other cars in that category that  exploit
  the allowable mods better.


Q:I'm  interested in moving up from autox slowly  to  obtain
  the  SCCA Competition license later on and do some amateur
  weekend racing?.


A:I'd  suggest starting out in a Stock vehicle.  An  option,
  if  you really intend to eventually go road racing, is  to
  look for an inexpensive road racing vehicle like a Vee  or
  an  IT  car, and run it as an autocrosser while  learning;
  then  when you're ready for SCCA racing school, you should
  already  have a reliable, well understood vehicle in  your
  possession.


Q:What   type  of  car  racing  are  available  (for  normal
  mortals) in the US?
A:The  SCCA  defined several types of racing,  open  to  the
  "public":


  Solo  I is a high speed event, using cars prepared to road
  racing  safety standards; it covers both hill  climbs  and
  race  track based events.  Solo I (and Solo II)  are  time
  trials; there is no wheel-to-wheel action involved.


  Solo  II is a moderate speed event; it corresponds roughly
  to  what  other clubs call autocross. Safety equipment  is
  not  mandated,  except for roll bars in  heavily  prepared
  convertibles (stock convertibles do not require roll  bars
  in Solo II.)


Q:What is autocross (Solo II)?
A:Autocrossing  (or,  Solo  II)  is  timed   racing   in   a
  controlled  situation where the agility of your  car,  and
  your  ability  as  a driver, are more important  that  raw
  horsepower.  Autox  courses are  usually  setup  in  large
  parking lots with orange traffic cones. Unless the  course
  is  pretty long, only one car is allowed on the course  at
  any  time,  which  means that there's  no  possibility  of
  going   fender-to-fender  with  another  car.   Cars   are
  classed,   either   by  the  local   group   (if   they're
  independent) or by the Sports Car Club of America  (SCCA),
  according      to     their     level      of      vehicle
  preparation/modification called categories (Stock,  Street
  Prepared,  Prepared and Modified, or S, SP, P, M)  and  by
  their performance characteristics, i.e., class. There  are
  9  stock classes from SS (Super Stock) down to H Stock, SP
  and M go from A-E, but P goes A-F.


  There  is a new category that some SCCA regions are  using
  called  SM  or Street Modified (aka "Open Street Prepared"
  in  some  regions). This is for cars that do  not  fit  in
  Street  Prepared  but  are  not competitive  for  Prepared
  class.


  Stock  class  was originally intended to be  a  place  for
  novice  autox-ers  to   "run what they  bring",  and  many
  local  clubs  have special classes for novice  competitors
  to   compete  in  for  their  first  year.   The   current
  situation for the Stock Category is that it has become  BY
  FAR  the  most  intense competition is in Stock  Category,
  followed by  Street Prepared.


  The  two  other  categories  are  Prepared  (mostly  race-
  prepped  production cars) and Modified  (open  wheel  cars
  and  production cars with major engine transplants, etc.).
  The   preparation  allowances  for  Stock   Category   are
  somewhat  more  liberal than one might  guess:  any  front
  swaybar  may be used, and adjustable suspensions  are  not
  required  to be adjusted to factory specs. As an  example,
  the  VW  GTI  that I run typically is set to 2.25  degrees
  negative  camber  and  3/16" toe  out  at  the  front.  In
  addition,   you  need  autocross  tires   to   be   really
  competitive, and these tires are worthless for any  street
  use.  Most  serious competitors in Stock  Category  buy  a
  second set of wheels and mount autocross tires. The  above
  notwithstanding,   autocross  competition   is   amazingly
  challenging  and fun, as long as you understand  that  you
  won't  be  winning any trophies until you get  some  "seat
  time". I highly recommend the activity.


  At  the beginning of the autox season most clubs also hold
  novice driver  schools which teach you the basics (how  to
  follow  the course, how cars are  staged on the grid,  how
  to  be  a  course worker, safety issues, etc.).   All  you
  need  to compete in most places is a street-legal car that
  can  pass  a  basic safety inspection and a valid  drivers
  license; you're required to wear a helmet (DOT or  Schnell
  75  approved) when you race, but there are usually  loaner
  helmets  available  for you to borrow  when  you're  first
  getting started.


  There's  an  Internet-based  group  of  autox-ers   called
  "Team.Net"  (the "dot" is pronounced) who have  a  mailing
  list  and  an ftp archive to promote discussion of  autox-
  related issues.
  Send  email to "autox-requ…@autox.team.net" or  in  case
  of  failure,  use  autox-requ…@triumph.cs.utah.edu  (the
  former  hoosier  address has been  decommissioned)  to  be
  added  to  the list. Also, call the SCCA ((303)  694-7222)
  and  ask  for  the Solo II contact person in your  region;
  they  should  provide you this person's phone number,  and
  you  can  call  this person to find out  when  events  are
  scheduled.


  Contributors:
  [Blake Sobiloff <sobil…@lap.umd.edu>]
  [jay.mitch…@the-matrix.com (Jay Mitchell)]
  [Jonathan Dove <j…@gsvms2.cc.gasou.edu>]


Q:What are the allowable mods for each auto-x category?
A:Stock:
  Cars  must  run  "as specified by the manufacturer,"  with
  the  exception  of  specific allowances. These  allowances
  include [jay.mitchell]:
1. The use of any front swaybar.
2.  Any  suspension  adjustment IF  the  manufacturer  makes
  provision for adjustment for non-competition purposes.
3.  Any  shock  absorber that is does not change  suspension
  geometry  or  alter the range of travel  (i.e.,  must  use
  original  mounting position).  I [jay.mitchell] use  Konis
  on  my  A2  VWs, and the Nationals-winning cars  have  all
  used Konis as well.
4. An aftermarket steering wheel within 1" total diameter of
  the  stock wheel. Wheels with airbags may not be  changed,
  and  cars made after model year 1990 must retain the stock
  steering wheel.
5.  Road  wheels of the stock diameter and width with offset
  within  +/- 1/4" of stock. This is a useful allowance,  as
  it  allows wheels with 32mm offset on 8V GTIs and  Jettas,
  widening the track by a total of 1/2".
6.Any brake lining material.
7.Certain  engine  "blueprinting" practices, although  these
  are  rapidly  being phased out. Cars model  year  '92  and
  newer  may not overbore/balance, and all cars starting  in
  1/1/95 this is not allowed.
8.The  use  of  any DOT-legal "street" tire. The hot  setups
  are  BFG  COmp  T/A R1s or Yokohama A008RSIIs,  and  these
  tires  are stickier than pure racing rain tires were  five
  years ago! [Jonathan Dove]:
9.Ignition timing must be within factory setting
10Can  change the exhaust system behind catalytic  converter
  (if equipped) or exhaust manifold.
11Allows the use of roll cages.


  Other  than  the above modifications, you  have  to  leave
  your  car  pretty  much as it was manufactured  in  Stock,
  including  the  original driver's  seat,  body  trim  (you
  could  add non-aerodynamic appearance bits, but you  could
  NOT  remove  original trim), battery  location  and  size,
  except  for loose  items, such as the jack and spare  tire
  which may be removed.


Street Prepared:
================


(Basically the same as stock except for these)


Street  Prepared was originally intended as  an  incremental
step  beyond Stock prep levels. As it now stands,  a  really
competitive  Street Prepared car will neither be  legal  nor
practical for street use. Tires must still be DOT legal.  In
addition  to  Stock allowances, Street Prepared  allows  the
following:


1.Replacement  or modification of stock springs. Replacement
  springs  must be of the same type (coil, leaf, or  torsion
  bar)  and in the same location, as original, but the rate,
  free length, and coil diameter may vary from stock.


2.Installation of camber plates in strut suspensions.


3.      Installation  of body stressbars. There  are  strict
  limitations  on  the  type of "strut brace"  that  may  be
  installed,  but  some  of the most common  ones  (Neuspeed
  front bars, for example) are legal.


4.     The use of any wheel size and/or offset.


5.The  use  of  any intake and/or exhaust system  that  will
  attach  to  the  original, unmodified  engine,  i.e.,  the
  cylinder  head may not be mcahined or drilled to accept  a
  non-stock manifold.


6.The alteration or removal of emission control devices.


7.The  installation  of  any fully  padded  and  upholstered
  driver and front passenger seat.


8.The installation of any steering wheel.


9.The use of a limited slip differential.


10The  use  of  any flywheel, clutch, pressure plate,  etc.,
  that will bolt to the stock crankshaft.


11The  use  of  any ignition system, including a crank  fire
  system on a car not originally so equipped.


12Ignition timing can be set outside factory specs.


Prepared:
========


Prepared  Category  is structured around  SCCA  club  racing
preparation  allowances for Production  and  GT  class  race
cars. Prepared cars typically have all interior trim removed
(not  allowed in Stock or Street Prepared), roll cages, full
racing  suspensions, highly modified engines, and  they  can
run  on racing slicks. A list of allowances would be far too
long  to  itemize here, and you have to have both a Solo  II
rulebook and the General Competition Rules to determine  the
legality of any particular modification to a car.


  The following was supplied by Richard Welty:
  Production  is  a road race class; although  stagnant  for
  many  years, there is now change occuring here.  the  cars
  in production are substantially
  different from their road-going cousins.


  GT:  these are generally tube framed cars with sheet metal
  that resembles a road going car; there are 5 classes,  GT-
  1  through GT-5.  GT-1 contains corvettes, camaros,  etc.,
  and  GT-5  contains  things  like  Minis,  and  there  are
  various cars in between.


  Sports  Racers:  these are single-seat,  closed  fendered,
  special  purpose  race  cars.   there  are  a  number   of
  subclasses  which  are quite different  from  each  other:
  Sports  2000, C Sports Racer, D Sports Racer, Spec  Racer,
  Shelby Can Am, and so forth…


  Formula  Cars:  these are the single seat, open  fendered,
  special purpose race cars. like sports racers, there is  a
  lot   of  variation  in  the  subclasses,  which  include:
  Formula  V  (based  on air cooled VW parts),  Formula  440
  (based  on 2 stroke motors and CVTs), Formula Ford  (based
  on   1600cc   Ford   motors),   Formula   Continental   (a
  conglomeration of various older winged Formula cars),  and
  Formula Atlantic.


  Showroom   Stock:   a  class  where  theoretically   stock
  vehicles   of   recent  vintage  come  together   and   do
  experiments  in  clever,  difficult  to  detect  cheating.
  Supposed to be cheap, but ends up being expensive.


  A  more  elaborate entry by Bob April: SCCA has a form  of
  racing, Showroom Stock, that purports to be exactly  that.
  Outside   of   a   roll   cage,  fire  extinguisher,   and
  competition  harness,  the car  is  supposed  to  be  dead
  stock.   Even the adjustments (such as front wheel camber)
  must  be  set  to factory specs.  Cars must be  relatively
  new.   In my experience (some years back) 1/3 of the  cars
  were  legal, 1/3 had fudges which probably didn't  matter,
  and  1/3 cheated like hell.  You can be in the first third
  (I  was)  and still have fun.  You get to race  at  places
  you  see on TV (Watkins Glen, Road America, etc.) I  drove
  the  car to the track, put numbers on with contact  paper,
  and  had  a ball.  In circa 50 races I had to get the  car
  towed  from  the track three times (one head  gasket,  one
  destroyed clutch, one large hole in engine block with  rod
  sticking  out), although I also once drove  an  X1/9  back
  400  miles in 3rd gear (only), towing a small trailer with
  race  tires and tools.  The driver must join SCCA, have  a
  routine  physical,  and  have  a  helmet,  firesuit,   and
  gloves.   Figure  $1000-$2000 to prepare car  and  driver.
  Major  maintenance costs are tires and bodywork,  and  you
  have  some control over the latter.  Totalling the car  is
  rare, but it happens.  Getting hurt is much rarer, but  it
  happens.   You  go  through  two  weekends  (schools)   of
  supervised  practice  and mock  races  and  get  to  enter
  Regional races.  Successfully complete these and  you  get
  to  enter National races.  Once you have the license,  you
  can  show up in a Formula Atlantic (the worst safety  flaw
  in the whole thing).


  Improved  Touring:  a class where battered,  rusty  sedans
  built  between  1968 and about 5 years ago come  to  trade
  paint.   Everybody is sure that the guy who just beat  him
  is  cheating, but nobody can afford to post the tear  down
  bond.  loads  of fun, actually, but watch out  for  Volvos
  from Hell.


  Improved Touring allows for  typical (wheels, bars,  etc.)
  mods.   The  drawback is you'll work on the car,  and  not
  learn  racing nearly as fast.  Be like a Formula 1 driver;
  just  show  up and drive.  For more info, call  SCCA.   If
  you  can't  find  the number, you don't  have  the  proper
  attitude to do this; it takes a _lot_ of perseverance.


  American  Sedan:  Big  bore version of  Improved  Touring;
  Five liter Mustangs, Camaros, and Firebirds trade paint.


Modified
=======


Modified Category has five classes, including three intended
primarily  for  open wheel race cars and two for  production
based   cars   that  have  been  modified  beyond   Prepared
allowances. In this class, the sky is the limit (almost). In
my  region, we have two Datsun Z cars with Chevy V8s  and  a
heavily  turbocharged  Miata  in  Modified,  as  well  as  a
fiberglass  GT-40 lookalike kit car. Popular  Modified  cars
include Formula Fords, Formula Vees, and F440s.


The  SCCA  publishes the Solo I and II Rules in a book  that
costs  about $10 (for nonmembers, less if you are a member).
The  rules are updated annually and the current year's rules
are  available beginning in January. The above  descriptions
are  general and NOT comprehensive: if you are contemplating
modifications to your car for Solo competition,  I  strongly
recommend that you buy a rulebook. Happy conehunting!


Q:What are the Solo II Classifications for VWs?
A:Here  is  a list of popular VWs, along with their Solo  II
  Classifications:


Car                      Stock     Street P  Prepared
Rabbit/Jetta, GTI (A1)   ES        DSP       EP
Rab PU/Fox               HS        ???       ???
8V Golf/Jetta, GTI(A2)   ES        DSP       EP
All 16V                  ES        CSP       EP
Corrado G60              DS        ASP       EP
Corrado SLC              CS        ASP       EP
Passat GL                HS        DSP       EP
Passat VR6/GLX           GS        DSP       EP
Golf/Jetta III,          HS        N/A       N/A


Q:What  are  the  addresses  for  some  of  the  performance
  related clubs?
A:


  Sports  Car  Club  of America, SCCA, (General  Car  Club),
  USA, (800) 255 5550


  SCCA  Cal  Club,  LA/OC area, Hotline (818)  988-RACE,  or
  contact:
       Lin Jensen     (818) 309 95 91
       Renee Angel    (909) 947 06 44
       Ric       (310) 496 39 50
       Solo      (714) 539 22 57


  SCCA Cal Club, San Diego, Hotline (619) 441 13 33


Q:What are the some of the performance driving schools?
A:Some testimonials from Ed Priest:


  If  you  can afford it go to a Track Time driving  school.
  Cost  approx $500 for two days of instruction and time  on
  the  racing track of your choice. You learn a lot and it's
  a  hell  of  a good time. I've gone twice at Road  America
  and am going to take the class at Laguna Saca this fall.


  The  cost is a lot less expensive then Skip Barber and the
  rest  because  you drive your own car - which  is  what  I
  wanted anyway. It's really good to find out what your  own
  car  feels  like and does at the limit. The good  news  is
  that most of the insurance companies cover you during  the
  class for no extra charge.


                          CHEMICALS


Q:What is Rain-X? Does it work?
A: It's a chemical to treat your windshield to repell water.
  Above  certain  speeds raindrops will just slide  off  the
  windshield  making wipers almost redundant.  This  product
  is  used on airplanes. Peoples experiences vary with  this
  product.  It works well on some  windshields or  types  of
  glass  (most  VWs  seem ok) not too well  on  others  (for
  example,  it will have no effect on headlights).   In  all
  situations,  it  will only last for a couple  of  thousand
  miles.   Some  have reported that it forms a haze  on  the
  wildshield.  I  believe that part of the  trick  to  apply
  this   product  right  is  to  start  with  a  very  clean
  windshield   (use  alcohol  as  a  final  degreaser),   at
  temperature (18C or 70F) and use extremely clean soft  non
  greasy cotton cloth.
<Synthetic lubricants, etc>


Q:Can and should I use synthetic motor oils?
A:  First  have  a look at the archive on this.   In  short,
  synthetic  motor  oils  are superior  in  all  respect  to
  mineral based oils. However, with regular oils being  very
  good  already,  the  chances of  you  experiencing  engine
  failure  because  of  oil  viscosity  breakdown  or  other
  factors  have  become extremely rare under normal  driving
  conditions.  Usually,  the rest  of  the  cars  wears  out
  first.
  However,  under  higher stress conditions, synthetic  oils
  will  provide  you  with  better protection.   Because  of
  their  better flow properties, synthetics are also  better
  at  start  up, better in colder climates, and consequently
  provide  a  bit  more  power  (measurable,  possibly   not
  noticable). One of the major concerns with synthetic  oils
  is  compatibility  with seals. The newer  cars  definitely
  have  seals which are compatible, with older cars this  is
  less  certain. The general recommendation with oil  change
  intervals  is  to  remain with the car's  recommendations.
  With current VWs this is every 7500 miles or 12 000 km.
  The  extra  cost  of  synthetic oils is  negligable   when
  compared to other vehicle operating costs including  fuel,
  insurance,  maintenance, and depreciation.   Mobil  claims
  that  the  superior engine protection, and reduced  strain
  on   batteries  and starters, synthetic oils  will  easily
  pay for itself over  the life of the car.


                     REFERENCE MATERIAL


A nice contribution by Bob April [Edited]:


The following books have been worthwhile to me.  In general,
they  are like a college education; after you have read them
you will be better positioned to make specific decisions.


"Volkswagen Water-Cooled, Front-Drive Performance Book" Greg
Raven, Available from US mailorder houses. Probably the most
relevant book for Water Cooled VWs.


"How  to  Make  Your Car Handle", Fred Puhn.   Explains  the
basics  of car dynamics, why you would want to make  certain
modifications, and how to do some of them.


"Prepare  to  Win",  "Tune to Win",  Carroll  Smith.   After
reading  "Prepare to Win" you will know how to  modify  your
chassis  safely,  i.e. why banging bolts  in  place  with  a
hammer is bad, and what to do instead.  You will also  learn
to  recognize quality performance parts as compared to cheap
junk.   "Tune to Win" is the postgraduate follow up  to  the
Puhn  book.   I  never would have considered accelerating  a
rear  wheel  drive car to get out of an oversteer situation.
Learn  why  a Formula V race car has a rear roll  bar  where
your car has an _anti_roll bar.


"Racing Engine Preparation", Waddell Wilson and Steve Smith.
Old, and discusses V-8s, but there's a lot of stuff you  can
use.   Waddell's  engines  have  been  around  Daytona  many
thousands of times.


"Bosch  Fuel Injection & Engine Management", Charles Probst.
Incredibly  clear  descriptions  of  the  systems,  way  too
conservative in describing and valuing modifications.


"Brake  Handbook", Fred Puhn.  If you're going  to  do  more
than change fluid and pads.


"Clutch  and Flywheel Handbook", Tom Monroe.  In conjunction
with the shop manual, explained why it was a really bad idea
to speed shift my X1/9 at autocrosses.


"Secrets of Autocrossing", Watts.


"The  Front-Wheel Drive High-Performance Advantage", by Jack
Doo,   ISBN   #   0-87938-298-8,  Motorbooks  International,
Osceola, Wisconsion


Monthly/Quaterly Publications:


European  Car (formerly VW Porsche): Argus Publishers  Corp,
P.O.  Box 452, Mt. Morris, IL 61054-0452 800-877-5602.  Most
relevant  mag in US, [W-VWs & other European cars] Addressed
from here on as [EC].


EuroSport  Car,  McMullen Publishing, 774 S. Placentia  Ave,
Placentia,  CA 92670, (714) 572 22 55, fax (714)  572  1864.
New  magazine.  First issue published in fall 93,  published
quarterly.  A  direct,  though less refined  (busty  babes),
competitor   of  [EC].  Many  articles  are  almost   direct
duplicates of what appeared in [EC]. Addressed from here  on
as [ESC].


                           ENGINE


Q:How can I get more power out my VW?
A:Buy  an SLC :->. It's an FAQ that's worthy of a book,  and
  that's  probably  where you should  start.  After  you  go
  through  this FAQ to give you some general idea,  look  at
  the following archives:


Corrado_Power_Upgrades   = Summary of available G60/SLC/VR6
                         Power Upgrades
Fox_Performance          = Fox performance upgrades.
Passat_restrictor        = Remove air intake restrictor for more
                         power (G60/SLC)
Repco_MetalMasters       = Experiences with these brake pads
Suspension_Mods          = Experiences & explanations.
Synthetic_Oils           = Technical papers on oils
VR6_Variable_Intake      = Description of the VR6 variable
                         intake manifold.
collins_1                = R.Collins (ex Drake employee) on VW
                         performance
collins_2                (mostly A1 & A2 GTIs)
collins_3
collins_4
collins_5
collins_misc1            = Misc. R.Collins communications.
collins_misc2
faq.radar                = You'll need it.
faq.tires.sizes          = General info on tires (sizes mostly)
faq.tires.survey         = General info on tires (net survey &
                         summary)


Following  are a couple of old known modification which  are
easy  & relatively inexpensive that will increase the  power
of  the car. In general, the older the car the more room for
improvement.  Newer  VWs  have  much  less  room  for   easy
improvements  because  many of  the components  are  already
near optimal.
One easy upgrade path for older VWs is therefore to look  at
newer  VW (Audi) models, see what they did, and see  if  you
can  swap parts. For example, older VWs have the restrictive
exhaust systems, swapping it with a large diameter one  from
a newer model (if possible) or using the catalytic converter
from an SLC will help.
Also  be aware when buying "performance" components on their
true  benefit.  Usually the top horse power gain  is  quoted
while  ignoring the rest of the power band.   Your  car  may
have more top end (high RPMs) while sacrificing power at the
low  end  (low  rpms)  which is where  most  street  driving
occurs.  The over all effect may therefore be that  the  car
may  actually  feel slower off the line, but be  great  when
passing another car.


So  first  decide where you want to improve,  then  research
whether the component in question really achieves that. Also
select performance parts that fit in the stock position over
those that do not. This is probably more true for suspension
components  than engine components, but is  a  good  general
rule  to  follow.  Parts that deviate too much  may  require
extensive  modifications, sacrifice reliability,  make  more
noise, or may even render you car unsafe.


In  general:  Reduce  the exhaust backpressure  (performance
exhaust)   Advance   the   timing  (recurved   distributors,
chips…)  Improve  breathability (K&N  Filter,  head  port,
throttle  body,  compressor) Add a hotter  cam  Enlarge  the
engine (change head, pistons, crank) Replace the engine with
a more powerful one.


All  cars: Use a K&N Filtercharger air filter element  (some
will  argue  whether  this makes any difference).  High  end
improves  a  bit. Corrados: 3 HP gain at top. Replacing  the
airbox  with  a  filter at the end of the  air  intake  also
provides  some  additional gain (but you'll also  hear  more
engine noise…).


Use synthetic oils (motor and transmission).


83-84 GTI:
  Change throttle body with a bigger one (Audi?).


  [From Peter Tong]: You can get one from a later Audi  5000
  of  the  aerodynamic  body style.   I  think  82  and  up.
  Another good donor car is the '85 Golf or a Golf that  had
  CIS-lambda.   You  have  to seal/cap  off  a  vacuum  line
  coming  off  it,  and  in almost all cases  transfer  your
  throttle  linkage from your '84 TB to the  new  TB.   Just
  make  sure  that  the  newer throttle  body  has  a  screw
  adjustment for the idle speed.  You also want to  purchase
  a  really small l screw driver/flat bladed screwdriver bit
  to adjust the idle.  On the 84s the idle adjustment was  a
  hex  that was easily adjusted on the newer TBs its a screw
  and  with  the  TB  mounted on your current  manifold  its
  harder to adjust the idle.  You also want to make a  plate
  to  put between the new TB and your old manifold to smooth
  airflow  (your 84 manifold has a TB opening  that  doesn't
  match  the newer larger TB).  Buy an old style TB  gasket,
  and  a  newer  style gasket, perhaps new 6mm allen  bucket
  bolts to attach it,  and make the plate to go between  it.
  If  you  want a plate cheap just send me $5 and I'll  send
  you  my  old one (I had my intake manifold ported and  the
  opening opened up).
  BTW,  even with a Fox manifold the TB is good for at  most
  4hp.


84-87 Scirocco (US):
  For  the  JH  1.8  big-valve  engine,  use  a  dual-outlet
  exhaust  manifold from any early car up to  '81,  get  the
  short  TT's  downpipe (retain cat) for 10 HP, with  a  17%
  gain  at  4200  rpm  and more torque  Optionally:  replace
  exhaust system from the cat back (US$150) & factory VW  g-
  grind camshaft (Autotech, $99)


  [From  Peter Tong]: What is the difference between the  TT
  downpipe  and the downpipe that come stock with  the  dual
  outlet manifold on earlier cars?


  The  length  is different.  The diameter is smaller.   The
  bends  are  slightly  more  abrupt  in  most  cases  (some
  aftermarket  replacement  downpipes  aren't  mandrel  bent
  even  with  inner side radius' slightly pinched  in).   On
  most  of  the  earlier cars with cats the stock  downpipes
  mated  before  the  cat  with a  flexpipe.   The  flexpipe
  doesn't  hurt  flow much but is of smaller diameter.  Also
  the  position of the collector on the stock pipe  is  such
  that  it would help at higher rpm - the problem is the  dp
  diameter  is  too small to support the flow  at  that  rpm
  (this  is  from my experience).  In the end count  on  the
  stock dp getting really restrictive around 115hp.  When  I
  first  put my 2.0 in and was really revving it - the  back
  pressure from the stock dp combo was so much that  I  blew
  a  nickel  sized hole it it!  This happened even though  I
  was  running a 2" exhaust and supertrapp rear of the  cat.
  Kind  of funny but it happened to seak out the weakest  pt
  on  my  stock dp and took it out.     The stock  dps  also
  have  two  welding  methods that  I've  seen  holding  the
  exhaust manifold flange mating surface.  One uses a  small
  metal  "brace" the other type is just welded to the  pipe.
  The  TT downpipe is nicely made and has worked well on  my
  car.   It  is stiff in many ways compared with  the  stock
  system,  and  tends to transmit more vibrations  than  the
  stock   system  (perhaps  due  to  the  stiffness).    The
  collector  joins about 2.5-3" before the  cat  and  is  2"
  diameter  pipe.   Tubing is mandrel bent  and  the  angles
  aren't  quite  as  severe as on the stock  dp.   Also  you
  eliminate  the flexpipe with the TT cat dp.  What  did  it
  do?   When  I installed it - the midrange really improved.
  Top end also to a lesser degree.


  As for actual #s for what they did on my car:
        40-60 in 3rd gear: 4.6s before and 4.3 after.   This
  tests 3k to 4.5k rpm.
        50-70  in 4th gear: 7.9s before and 7.5 after.   3rd
  is 1.29 and 4th is .91.
       r&p is 3.89.


  So  you  can  see it improved the midrange by about  a  6%
  average. Is it worth $115?  It is I guess - it depends  on
  if  you are a geek like I am at trying to extract as  much
  out  of your engine as possible.  As it is that pipe,  the
  G-grind  and  the  TT  adjust cam sprocket  are  the  only
  aftermarket items that were necessary for me to  purchase.
  Oh BTW, fuel economy should improve slightly as well.


Fox:
  Remove  exhaust restrictor (see also further and  EuroCar:
  April 89, Aug. 89, Dec. 89, Apr. 90, Aug. 90)


90-92 Passat (4 Cyl):
  Remove air-intake restrictor, APS Chip, cam. APS chip  for
  automatics that is supposed to do wonders for low end  and
  shift  points. Applicable to all cars with 9A engine (inc.
  16V GLI).


85-92 8VGolfs/Jettas:
  The  biggest gain can be had with a better down  pipe  and
  exhaust system.


85 GTI:
  Change  ignition map by cutting wire #11?? on the ignition
  control  unit  and  grounding #3 (which was  connected  to
  #11). Yields 2 HP additional, torque peak occurring  at  a
  lower rpm. See also 85-87 GTI for additional power.


85-87 GTI: KE-Jetronics:
  Advance  ignition idle timing to 12 degrees BTDC or  until
  knock.  (factory specifies 6 degrees +/- 2). Gains 5-8  HP
  with  >=  92 octane fuel, very noticeable at the low  end.
  Note, it may reduce the life of your catalytic converter.


90-92 16V GTI/GLI:
  Motronic Power chips from Autothority & APS.


Corrado G60:
  Stage  1,  2 & 3 chips/packages from APS & Autothority  (&
  others).
  Stage 1/P-Chip:  Chip  swap, improves low  end  by  torque
        18%,   high  end  by          ~5%.  Gas  consumption
        improves but you do need Super Unleaded.     One  of
        the BEST improvements you can make to this car.
  Stage 2:   Pulley  change,  chip & fuel pressur  regulator
        (AT)  or exhaust (APS) => Power boosted to 180 (APS)
        or 200 (AT).
        Noisy,  too  powerful  for  the  car,  APS  is  more
        drivable,
        AT's not CARB approved. Gas consumption near stock.
  Stage 3:  Like Stage 2 but with a cam, affects mostly high
        end.


  Remove  cold air snorkel (too restrictive) => 1-2 HP  gain
        at the top end (Note: WAY too noisy).


  See also archive Cor_Power_Upgrades or something.


VR6  2.8l  & 2.9l Models (Corrado SLC/VR6, Passat GLX,  Golf
III, Jetta/Vento):
  Power  chips  available  from both  APS  &  AutoThority  &
  others.


  Stage I/P-chip:  Gain  of  7-10 HP at the  top  end.  Most
        people  reported little or no gain. AT's chip  seems
        to   produce  knock.  Replace  throttle   body   w/o
        internal air ramp (10% more airflow).


  K&N P-Flow filter. APS recommends the above 3 combined  to
        produce  the  best effect  to produce an  additional
        30 HP.


  Remove cold air snorkel (too restrictive).


  Use VW  Motorsport's  Variable Inlet Manifold  (VSR).  See
        archive  on  this. An alleged gain of  30-50  HP  at
        3000  rpm! Expensive (2300US$), but chances are that
        certain shops may produce a low cost immitation.



>>>Probably LOTS MORE…


Caveat: Most of the above are merely small fixes that do not
require replacement of a major engine component such as the
cam or the exhaust system, which is usually the next step
towards major engine improvements. Those enhancements
require a lot more work and expertise to install.

Caveat II: Most of the above improvements are approved by
the air resource boards for street legal use, but some are
not (Stage II, Corrado). Before you install any equipment,
make sure that you understand the full implications.
Tampering with pollution control equipment is a serious
crime, punishable with a 20 000 US$ fine in many states of
the USA.


Q:What's a K&N air filter?
A:  It's a washable (i.e., reusable) air filter made out  of
  an  oiled cloth like material over a wire mesh matrix.  It
  is  supposed  to let through more air while retaining  the
  same  filtering  capabilities. More  air  =>  more  power,
  especially at higher rpms.


  In  practice however, the reviews have been mixed. Hot VWs
  (Dec  92)  reported a 3-5 HP gain on the  high  end  in  a
  Jetta.  Others  have  reported no  difference  or  even  a
  slight  degrade in performance. My *speculation*  is  that
  some  cars  require to see some vacuum to  get  the  right
  amount  of  fuel,  kind-a like a choke  (e.g.,  carbureted
  cars).  The  same  is  true with  some  FI  cars  (measure
  vacuum) while other FI cars measure air flow. By the  way,
  a  3-5 HP difference is within normal daily variance of an
  engine  because of external factors such as  gas  quality,
  viscosity of the oil, ambient temp, etc. You can  probably
  gain  as much from pumping up your tires harder to  reduce
  rolling resistance (but increase wear).


Q:How do I service a K&N air filter?
A:  You  can buy the K&N chemicals (cleaner and reoiler)  or
  you  can  use  a  detergent called Formula 409  (used  for
  cleaning  kitchens in the US) to save some money (the  K&N
  cleaner  is  rumored to be the same as Formula  409).  You
  should always use their oil though. Also do not rinse  the
  filter in hot water. It'll shrink the cloth.


Q:How do I keep my engine cool?
A:  Keeping your engine sufficiently cool is needed for  all
  the  obvious reasons.  VW engines like to run hot, and are
  more  efficient  that way. However, under high  stress  or
  race   conditions,   the  factory  system   may   not   be
  sufficient.  If you run too hot your power is reduced  due
  to engine knock.
  There  are  several  ways  to aleviate  this  problem:  1)
  Increase  heat transfer with a different cooling fluid  or
  wetting  agent. 2) Increase the cooling capicity  of  your
  car with a larger radiator.
  The  reason  why I do not mention changing the  thermostat
  to  a  lower  temp one  is because it merely  reduces  the
  average  operating temp (which may be too high), but  does
  not  change  cooling capacity. In extreme  conditions  the
  temp  rating  on  the thermostat is not  going  to  matter
  because they will all be fully open. It is however a  good
  idea  to  make sure that your thermostat still is  capable
  of opening fully at the intended temp.


Q:How  can  I  improve  heat transfer/what  are  alternative
  coolant fluids?
A:  Redline  sells  a  "wetting" agent as an  additive  that
  improves  heat  transfer. It comes  in  two  forms  solid,
  which  contains  phosphates,  and  liquid  w/o  phosphates
  (OK).  People  who have used it can't tell any  difference
  under normal driving conditions.


  Under  normal  street  use you will  not  see  any  change
  because  the thermostat is regulating the temp. It's  only
  when  you  exceed  the  capacity of your  system  and  the
  thermostat  is  all  the way open that the  wetting  agent
  will  have  an  effect. The wetting agent is  supposed  to
  improve  heat  transfer by reducing surface tension.  This
  is  important near the head where the coolant  my  locally
  boil.   The   little  gas  bubbles  however  impede   heat
  transfer,  which in turn may lead to knocking and  reduced
  engine  performance. Redline claims it can  reduce  engine
  temp   by   as  much  as  30F  (depending  on  the   anti-
  freeze/water  ratio, for a 50% mix it's closer  to  10F  I
  think).  The performance shop I bought it from  said  that
  its  good insurance when your car is put under heavy  duty
  (stuck  in  traffic  on a hot day, making  a  desert  run,
  autocross).


  An  other  alternative described in European Car (Oct  91)
  is  to  use  !pure!  propylene glycol that  has  a  higher
  boiling  point  than  ethylene glycol  though  worse  heat
  transfer  properties.  [borow…@hpspkla.spk.HP.com]   The
  higher power VW engines have a problem with pinging  under
  heavy load. This is due to the coolant boiling inside  the
  head.  Coolant  vapor is a very poor heat conductor.  This
  loss   of  cooling  causes  hot  spots  to  form  on   the
  combustion chamber side of the head, causing pinging.  The
  propylene  glycol does not boil, and this  cools  the  hot
  spots better. Thus, pinging is avoided, and more power  is
  available  if the timing is set to take advantage  of  the
  reduced  chance  for pinging. The cooling  system  is  NOT
  pressurized,  but  vented to boil residual  moisture  away
  (which  lowers the boiling pt). A kit to make  the  switch
  is  available  from: MECA Cooling Company [See  the  first
  general FAQ for address]


Q:Do  "Split Fire" (= name of a plug sold in the US,  not  a
  type of plug) plugs live up to their advertised claims?
A:  Responses from the net & tests by TT indicate: NO,  they
  are  actually worse than the recommended Bosch plugs. Note
  that  VW  recommends the use of tri- cathode  Bosch  plugs
  for  some  of  their  cars…so this  split-fire  idea  is
  rather  "old".  Apparently it's  covered  with  Techtonics
  "Amazing Dyno Stories: Parts to get and parts to forget".


Q:What net wisdom exists on exhaust systems?
A:  Gilette:  Good balance for street and autocross  &  last
  LONG.  Some will debate that this is the best (stainless).
  OEM  supplier  to VW. Leistritz: Good balance  for  street
  and  autocross. Galvanized. Note: Stock on VR6  Corrado  &
  Passats.   Supertrapps:  GREAT   for   road   racing   and
  autocrossing   but   way  too  loud  for   everyday   life
  (rgo…@UMASSD.EDU)  OEM: More  recent  VW  mufflers  have
  improved  to the point that little can be done to  improve
  them  in street legal performance or durability. Also keep
  in  mind  that VW now offers lifetime warrantee  on  their
  replacement  mufflers.  Avoid  Midas,  contrary  to  their
  commercials.
  See also the archives on this!


Q:Removing the restrictor in a VW Fox to get more power?
A:  There  is a steel doughnut going right before  the  cat.
  This  stock doughnut has a two inch (approx) hole  in  the
  center  for the exhaust to flow thru.  It can be  replaced
  with  a  doughnut with a 2 1/2" (approx) hole to make  the
  exhaust  breathe  a  bit easier.  Not a significant  power
  increase,   mind   you.   [m…@royko.Chicago.COM    (Marty
  Masters)]


Q:What is the relationship between torque and horsepower?
A:


     RPM * torque(ft-lb)
HP=   ———————-
     5252
  Anyone have the metric version? I am too lazy (i.e., kW  =
  Nm * RPM / 60?)


Q:Should I remove the catalytic converter?
A: Not if you want to remain street legal, and unlike in the
  early  70's, these devices have improved so much that  the
  loss   because  of  it  has  become  minimal.  Note:   The
  Catalytic  converter on the SLC is rumored to  be  one  of
  the  most  free flowing of any VW, and will provide  gains
  when  used  on  a  Passat (or possibly  other  cars).  New
  Dimensions is toying around with this.
  Note:  In  the  US  there is 20 000 US$ fine  for  messing
  around  with  emmissions control equipment. Of course  the
  chance of being caught is rather minimal.


                         ELECTRICAL


Q:How can I improve night visibility/increase light output?
A:  >>>>Need contributions here!!!!! It all depends what you
  are  starting  from, and in what country  you  live.  USA:
  Sealed  beam units till 84 required, "aerodynamic" allowed
  thereafter  but  must still conform to  a  rather  pointed
  spread.  3  DOT  nipples for alignment  required.  Canada:
  Same  as  USA.  Northern  Canada  has  slightly  different
  regulations.  Europe:  Sealed beams  forbidden.  Light  is
  more  evenly  distributed. Some countries  require  yellow
  lights,  and different settings for city, highway and  hi-
  beam lights.


  Beware  that whatever you do, you must NOT blind on coming
  traffic.  Some  of  the  suggestions  below  are  actually
  illegal  for  street use in the US. However, judging  from
  the  large  number of misaligned lights in  the  US,  your
  "illegal"  mods will be less blinding than  a  normal  but
  badly  aligned  set of lights. However,  oncoming  traffic
  may  automatically assume that you are blinding when  they
  see more than 2 lights on at once (+ it may be illegal  in
  some   states/driving  conditions).  EuroCar  had  several
  articles on lighting in 91/92.


  To improve visibility, try the following:
    •  Align  your headlights. See Bentley or your local  code
  for  specs. I   usually go a tad higher than the specs w/o
  blinding.
    •  Change to halogen lights (yes, some of the sealed  beam
  units are not even   halogen).
    •  Clean  the  inside of your non-sealed beam  units  with
  some  alcohol  on    some  cotton/rag  at  the  end  of  a
  wire/stick. (Pretty tricky.)
    •  Add  fog lights (very wide, low, but not far reaching).
  Set   up  correctly,    fog  lights  DO  NOT  blind,   per
  definition.  Don't buy generic brands, but   minimally  go
  for Bosch, Hella, Cibie and others.
    •  Add  driving lights (narrow and far reaching).  Set  up
  according  to  specs   these DO blind, however,  they  can
  often  be  set up lower so that blinding   can  be  almost
  entirely  eliminated. - Change to one  of  the  non-sealed
  aftermarket units, which are usually the   European  style
  lamps.
    •  Change  to  the equivalent European "aero-style"  units
  (e.g.,  A2 Jetta).   These are available from a number  of
  sources  and have much better beam   characteristics  than
  DOT  approved  lamps  provide. Your ability  to  use  them
  will  be  a  function of the level of  detail  your  state
  motor  vehicle   inspection requires. In NJ, they have  to
  come out to pass inspection [Tom   Coradeschi].
    •  Change  to poly ellipsoidal, high-energy, "DE"  lights.
  This  is  the  newest   technology in lighting technology,
  more  commonly found on newer BMWs   (though BMW  uses  an
  arc   lamp  rather  than  halogen).  EuroCar  had  several
  articles about these in 91/92.
    •  Change the wattage of your bulbs. This is actually  not
  always  a  good solution   because your lenses  may  crack
  because  of  heat  build-up, moisture accumulates  faster,
  wiring  may not be able to carry the load, may blind,  may
  not  fit  in all non-sealed units [According to Andy,  you
  cannot  not put higher wattage lightbulbs into  the  stock
  North American light lenses.


  [Unverified…jan]    The 70/90 Watt versions  of  the  H4
  can  be  bought  at off-road places such as    Competition
  Limited, (313) 464-1458 according to Dilmore.   There  are
  also  45/100W versions of the standard 45/65W lamps.  Some
  lamps  require you to trim a metal tab that would normally
  prevent their use for street cars.


  From  Michael R. Kim: I've got 80W low beams  on  H4,  and
  haven't had any problems being pulled over.  I drive  with
  friends a lot, and ever since installing the lights,  I've
  asked  them  about  glare, for fear of getting  a  ticket.
  They  told me that since I've angled them down just a tad,
  they  don't notice any more glare than a car with  factory
  lighting.   Mind  you, if you've ever seen  one  of  those
  Ford  F150  trucks,  with their lighting,  you'd  question
  about  proper light angling.  I've had the lights  in  now
  for  almost 5 months now, and have yet to even get a flick
  of  the  high  beams from someone else for  blinding  them
  with  80  W  beams.  I would definetly recommend upgrading
  lights,  it  can do wonders for your driving,  but  PLEASE
  double  check  your  alignment and  light  pattern  before
  going off to test how well they work.


                        TRANSMISSION


Q:Should I change to a racing clutch?
A:In  most  cases a racing clutch ("4 puck") is  really  not
  needed  for  street  or Autocross uses.  VW  clutches  can
  easily  handle well above stock power. Furthermore, racing
  clutches  are very harsh (like, all or nothing)  and  much
  stiffer  to depress. One of the more agreeable changes  is
  to  use  a  stronger pressure plate with  a  stock  clutch
  disc.


Q:What  transmission fluid should I use (manual  cars)?  Why
  is it important for racing?
A:If  you use a transverse engined car at a track for  speed
  events  (as opposed to a parking lot autocross),  you  may
  actually  be  in a corner long enough to slosh  oil  clean
  away  from  the pickup, with possible bad results  (please
  don't  ask  how I know).  The real solution is  to  get  a
  baffled  oil  pan, but synthetic oils will do better  than
  dino oils in this situation.


  As  far  as I know, most/all water cooled VW transmissions
  require  gear fluid with an API rating of GL-4 (MIL-2105).
  The  recommended GEAR viscosity hovers around 80W,  75W-80
  or  75W-90  Note  that 75W-80 GEAR oil  is  equivalent  to
  10W30  MOTOR oil, but it is NOT recommended to  use  motor
  oil  in gear boxes, even though some Japanese cars  do  so
  any  way (has to do with shear strength). GL-5 oil is made
  to  lubricate gears (like in a differential) and may cause
  premature wear on brass synchros.
  NOTE  that  GL-5 is recommended for the *differential*  on
  some  AUTOMATIC  VWs  and  on some  manual  transmissions.
  However  most VW *Manual* transmissions need  GL-4.  Check
  your user manual or VW.
  Quality  of  the  gear  oil makes  a  HUGE  difference  in
  shifting.  I  have  personally tried  Castrol  (HORRIBLE),
  SWEPCO  (Better), VW gear oil (good, I suspect  that  they
  use  a  synthetic in some cars), and Redline MTL (best  so
  far).  Others seem happy with Mobil 1, Synthoil,  Spectro,
  etc. How these oil affect transmission life is unknown  to
  me.  Note  that  MTL  is rated 75W80,  while  their  newer
  product MT90 has a rating of 75W90 which may be closer  to
  the required viscosity of your transmission.
  VW  also sells synthetic transmission oil (at US$20/liter)
  which is rumored to be very good as well.
  Most  VW  transmissions use somewhere around 2-2.5  liters
  of  oil. Before you drain, make sure you have something to
  catch  the oil (an old jumbo coffee can is perfect).  Open
  the  side fill hole first, because you'll have to fill  it
  up  to  either  the fill hole or BEYOND. You'll  therefore
  either  have a little bit leak out or 1/2 liter gush  out.
  To  drain  (the  rest), unscrew 17 mm allen  plug  at  the
  bottom   of   transmission.  To   fill,   either   unscrew
  speedometer cable or use the fill hole on the  side.  Some
  VWs  require the level of the oil to be just so that  some
  drips  out of the fill hole, others (some A2 Golfs/Jettas)
  require  an  additional 1/2 liter on top of  that.  That's
  why  it's a good idea to catch the old stuff and check the
  fill hole first.
  [NOTE: Some VW User's Manuals apparently do recommend  GL-
  5  in  some  transmissions, so check first! b…@cellar.org
  seems to be doing ok with Redline GL-5 after 100kmiles  in
  his car.]
  [NOTE:  One  recent  posting by (Paul Keller)  blames  his
  transmission  failure  on  MTL, and  claims  that  Redline
  recommends MT90 only for VWs. At this point it is  unclear
  to  me  whether  MTL is to blame, and whether  using  MT90
  would  have made much of a difference. Keep in  mind  that
  he  is  one of two so far which blame Redline out of  many
  who have had no problems so far.]
  TIP:  Glue  a  small round magnet on the  outside  of  the
  drain  plug.  They  can be bought cheaply  at  electronics
  stores,  and  it  will attract metal  particles  that  may
  damage  the transmission. Older VWs used to have  magnetic
  drain plugs, but VW stopped using them for some reason.
  Some  newer  VW  trannys now have  this  magnet  BUILT  in
  permanently.


Q:What's  the  difference between the normal  wheel  bearing
  grease and  Spectro SPL grease?
A:  The front bearings on VW's tend to take a lot more abuse
  than  on  other makes, so many people recommend  that  you
  use  a  synthetic like Spectro to help them  last  longer.
  However,  there  also seems to be some  confusion  on  the
  matter:  most normal drivers are easily able to  get  100K
  mi.  out  of their front bearings. This is in contrast  to
  racers,  who  may have to change bearings  every  race  or
  two,  and  to GM products, which are supposed to have  new
  bearings  every 50K mi. (according to a sign on  the  wall
  of   a  local  dealership).  [sobil…@lap.umd.edu  (Blake
  Sobiloff)]


                           BRAKES


How to improve/vented/cross drilled/pads


Q:What and why vented rotors?
A:  Braking  converts motion into heat.  Heat  needs  to  be
  dissipated. The faster you can dissipate heat  the  better
  you  can  stop,  and less fade. Vented rotors  essentially
  have  two parallel "discs" with an airspace in between  to
  increase  cooling.  Many  of the  Kesley-Hayes  non-vented
  front  rotors can be replaced with vented ones and thinner
  pads  without  replacing calipers for  a  slight  gain  in
  braking power.


Q:Why cross drilled rotors?
A:  Braking  produces  gasses, and cross drilling  give  the
  gasses   a  way  to  escape,  thereby  increasing  contact
  pressure.  Personally [Jan] I do not advice cross  drilled
  rotors  because of the increased likelihood  of  cracking.
  DO  NOT CROSS DRILL ROTORS YOURSELF. It's usually done  on
  an  NC  machine at calculated positions followed by stress
  relieving.


  The  comments from people on driller rotors are that  they
  improve  braking  under competitive situations,  but  only
  provide  a marginal benefit under normal street use.   The
  also  feel  more uneven when you brake (esp.  the  slotted
  ones) and are also noisier (they humm).


Q:Is it worthwhile changing my rear drums to disc brakes?
A:  For  normal purposes: NO. For racing and other purposes,
  maybe.  Considering  the  high  cost  of  this  swap   and
  considering that only 30% of all braking power comes  from
  the  rear, it is usually not worth the effort. Concentrate
  on the fronts instead.


Q:What are the benefits of steel braided brake lines?
A:  The  reports  I have received is that it improves  brake
  feel  marginally  (less expansion of the tubes)  but  that
  the steel is also subject to more corrosion.
  [According to Volney.Spald…@Corp.Sun.COM]: They are  not
  recommended  for street use. Reason: Lines are  rigid  and
  will  not  flex  with the body as it turns and  reacts  to
  road  imperfections–rubber hoses will. As a  result,  the
  lines can often get pinched and fail. Stainless lines  are
  OK  in  racing applications because race cars are  subject
  to  constant inspections/bleeding/maintenance. If there is
  an  alignment  problem it will likely be discovered.  Most
  people   probably  are  not  as  disciplined   in   street
  applications making the this mod impractical.


Q:What pads should I use?
A:  See the discussion in the technical FAQ and also in  the
  archives.   It  is important to realize that  "race  pads"
  (e.g., Ferrodo, to some degree, REPCO Metal Masters)  only
  work well when HOT, and are therefore not well suited  for
  calm  city  driving.  You WILL slide  through  your  first
  intersection in the morning with these pads.



>>>>VOLUNTEERS>>>>????? Needed: diagnosing problems


                    TIRES/RIMS/SUSPENSION

Q:I  want  to improve the handling of my VW? Where should  I
  start?
A:  Start  reading  back issues of EuroCar & VW  Performance
  books.  It all depends what you want and for what  purpose
  (street,  autocross, etc). In general  people  follow  the
  following  road  to  better  handling:  Tires  and   rims,
  shocks, sway bars,stress bars.


Tires & Rims:
————-


  Probably  the biggest single improvement you can  make  is
  by  changing the stock tires, and in some cases the  stock
  rims.  It  all depends how much money you have,  and  what
  you  have  as  stock equipment. If you want to  keep  your
  original  rims go to a stickier tire in the   stock  size.
  Next  step  up  is a wider tire with a lower aspect  ratio
  for  the  same rim, e.g., 165/80-13 to 175/70-13 (this  is
  called plus ZERO).
  To  make  a  more  significant impact, you  will  have  to
  change  rims  (but be aware that it may  put  you  into  a
  different auto-x category). Generally, you go with  larger
  rims  (in diameter) with lower profile tires (=> less tire
  flex  =>  better  handling) and also with wider  rims  (=>
  more   sidewall  rigidity)  and  wider  tires  (=>  larger
  contact  patch  on dry roads, more hydroplaning  on  wet).
  Most FWD VWs are made to be run with tires around 1816  mm
  circumference, so each time you go to another  combination
  you   try   to   stay  within  a  few  percent   of   this
  circumference  so  that your gear ratios  and  speedometer
  readings  remain the same. Odd as it may  seem,  rims  are
  still  measured in inches eventhough the rest of  the  car
  is metric…
  The  upgrade  gategories are called PLUS  ONE,  PLUS  TWO,
  PLUS  THREE,  and  so on, with each "+"  referring  to  an
  additional inch in rim diameter starting from  a  13"  rim
  as  a  base. Note therefore that many of the VWs  you  buy
  nowadays are already  at +1 or +2.


  Here's  M.  Sirota's  extensive  list  of  NOMINAL  sizes.
  Actual sizes vary:


Spec.     Side   Radius Diam.    Circumf.Revs/Mile Difference
          wall
BASE:
155/80-13 124mm  289mm  578mm    1816mm  886       0.0%
165/80-13 132mm  297mm  594mm    1867mm  862       2.8%


PLUS ZERO:
175/70-13 122mm  288mm  575mm    1807mm  891       -0.5%


PLUS ONE:
185/60-14 111mm  289mm  578mm    1815mm  887       -0.1%
195/60-14 117mm  295mm  590mm    1852mm  869       2.0%
205/55-14 113mm  291mm  581mm    1826mm  882       0.5%


PLUS TWO:
195/50-15 98mm   288mm  576mm    1810mm  889       -0.4%
205/50-15 102mm  293mm  586mm    1841mm  874       1.3%


PLUS TWO (MUD AND SNOW):
185/55-15 102mm  292mm  584mm    1836mm  876       1.1%


PLUS THREE:
225/40-16 <someone?>


  Going  from  165/80-13 to 205/50-15 will make an  enormous
  difference,  however  going from  195/50-15  to  205/50-15
  will  provide  less  of an improvement  (see  other  FAQ).
  There  are  also additional factors to take into  account.
  The  first  is that tires can only be fitted on rims  with
  certain rim width limts and secondly, there is a limit  on
  how  wide  a  rim AND tire will fit on your car  to  avoid
  rubbing  with the struts/shocks and fenders. The  last  is
  that  you also need to get a rim with the correct  offset.
  These are all explained further below:


TIP: [From Roy Kao] DON'T SKIMP OUT ON CHEAPER TIRES!!  An
investment
in good mags is useless with cheap tires.


Q:What are the rim width ranges per tire size?
A:  The  rim  ranges  per  tire width  (from  a  Euro-Tire's
  Catalog) are:


TIRE      RIM RANGE      Diameter
185/55-15 5"-7"          23.03"
195/55-15 5.5-7          23.43
195/50-15 5.5-7          22.72
205/50-15 5.5-7.5        23.11


Q:What  is  the largest rim/tire sizes that will fit  on  my
  VW?  A:  It  depends from model to model. Also, make  sure
  you  get  the  right  rim  offset  or  your  handling  may
  degrade.
  Scirocco  I: Front: 185 or 195 mm wide depending on  model
  Rear: 205 mm (?) Max Rim: 15"x6"
  Scirocco II: 205?
  Rabbit I: 205/60R13 will fit fine.
  Rabbits/Jetta: Usually > Scirocco!
  Golf/Jetta  II: 215/45R15 fits, at least  on  a  GTI  with
  flared  fenders. 15 x 6 & 195/50/15 fit also,  =?  GTI/GLI
  GTI/GLI: 215?
  Corrado:  Lower  rim  limit are  15"  rims  due  to  brake
  calipers
  16x7.5" rims with 205/45/ZR16  work fine.
  Tire limit =? 225
  EuroTire sells 15" steel rims for mounting snow tires.
  17" rims may rub and require to roll the fenders
  Passat: ?
  A3  Golf (EC March 1994): 7x15, 205/50, 35mm or better, 38
  mm offset. 16" rims: 215/40 R16. 225 are TOO large.


  Remember,  offset  is very important in  determining  tire
  fit!
  >>>ADD MORE ENTRIES>>>This needs to be improved [jan]


Q:What is rim offset? [D="EinpressTiefe" or "ET" Value]
A:  The  distance  between the rim's  center  line  and  its
  mount

Post

Back to the top
erm… :|

looks like some good info in there, but would be useful if you could edit it up to seperate posts etc.

Good thinking though  :) , i'm working on a Mk1 16V conversion FAq at the moment.

Mk1 Golf 16V Conversion FAQ Zip, now located at in the Forum WIKI section: http://vwgolfmk1.org.uk/index.php?page=cedi&type=misc&id=42%2F26%2F3
0 guests and 0 members have just viewed this: None.