Mellow Yellow 3.2ltr 24v Conversion

Got the headers and down pipe trial fitted. Perfect .

No problem with clearance under the car or steering boot but the tab on the steering rack is a pain. I'm hoping I can remove the tab in situe as don't fancy removing the rack again.

 

hi rich
regarding your radiator hoses. could you not mock up everything up that requies a hose. use plumbing solder or something similar that easy to bend and cut but keeps its shape. then have someone like viper proformance or other custom hose maker make them up. might work out cheaper than buying the kit.

clarkie-26 said

hi rich
regarding your radiator hoses. could you not mock up everything up that requies a hose. use plumbing solder or something similar that easy to bend and cut but keeps its shape. then have someone like viper proformance or other custom hose maker make them up. might work out cheaper than buying the kit.

Hi Clarkie,

That sounds like a good idea  

Only managed to work on my Golf this afternoon.

Wanted to remove the gear linkage bracket that was fouling my down pipe. Pretty tricky to do in situe but go there in the end.

So from this



To this:

Finished in satin black, wet in the photo but will dry dull like the original coating .

So this weekend I have been looking at the plumbing. I think I can make good the existing return pipe from the aux coolant pump to thermostat housing and radiator with a bit of cutting.



Got the shifter in place and lines run to the gearbox.



Installed the headers permanently and trial fitted the down pipe to get an idea of lambda position.



 

Looking good mate! Have you tried the gear shifting with this setup ? Wonder how it is, and would like a review

I have the 02A gearbox with hte other shiter tower, do you know if it swapable? I like the look of yours better…

Regarding your o2 sensors I placed mine in these positions. I will see if I can shoot i picture next time the car is in the air

Hummel I just posted the same picture in your thread lol

My gearbox is indeed an 02a from a Corrado but I took the nasty 02a shifter tower and replaced it with an 02j tower and the respective shifter cables and gear stick box. I will let you know how it goes. I think I can already spot an issue where it may foul the gearbox mount when in reverse. I need someone to test in the car and I can look at what it does. It probably needs 2mm ground back on the counter weight.

I'll mark up the down pipe on Thursday and cut and weld the bungs in.

I ended up ordering these from NTK



Thought it was weird why I had one Bosch lambda and one NTK. I guess the Bosch one is the regulating and NTK the diagnostic in the Stock engine. The car only came with 2 but I guess the seller didn't realise I needed the 2 front pre cats ones.
 

Got the lambda bungs welded up yesterday

Also a new alloy oil filter housing cap. Unfortunately someone decided to round off the alloy drain plug in the centre of my genuine plastic cap so an excuse for an upgrade 

I'm looking to get the exhaust system on and buttoned up next but does anyone know if you can get the plastic fuel lines and fittings for a Mk5 Golf separate and where from? Perhaps Hummel or rubjonny might know?

I'm going to use the mk5 return less fuel rail. Keep my existing fuel system which is lift pump from tank to swirl pot and then Bosch Gti pump to up front.

All sorted

Found the plastic hard line, connectors and a tool to apply them. Should arrive this week.

Your O2's looks spot on!  

Regarding the fuel lines, I just hoarded a vw on the junkyard for the connectors, and used AN fuel lines mounted with a clamp, works perfect.

I used the R32 golf mk5 fuel pump inside tank, feeded the mk5 filter through the original pipe in tank, and the return as well. This way I only have the fuel filter outside the tank and one fuel line to the engine, I thereby safe the lift pump.

My only downside is that I have trouble if the fuel is low in the tank and cornering hard, I'm working on a solution to this

Oh and remember you need the R32 fuel filter with build in FPR. And a return from it to tank.  

Hummel said

Oh and remember you need the R32 fuel filter with build in FPR. And a return from it to tank.  

Oh my fuel system is all sorted and have the correct fuel filter I'm using a new carb 1.1 fuel tank, cabriolet lift pump in tank to late cabriolet swirl pot located in GTI accumulator location feeding a GTI pump in stock location.

I have rubber lines for all the short sections but wanted to take plastic lines to the fuel rail etc and use proper quick connector connections on the filter.

I need to make room for the filter though and don't really want it in the engine bay.

 

Not a great deal done this week but gearing up for a big push to get the engine trial run.

Got the down pipe in place with the new lambda positions sorted.



Got the Miltek classic exhaust in place just to work out whats required to join between the exhaust and down pipe. Ordered up some parts which will come this week to finish that off including a flexi joint and compensator connection I already have. To make things interesting the down pipe is 2.5" and Miltek exhaust 2.25" but have is sussed.


Got a bleed valve / steam vent inline coolant line joiner to help bleed the system.



Finally almost got everything to update my fuel system. Instead of running the late cabriolet swirl pot I have an alloy 1 litre surge tank that the 044 Bosch pump fits into. This will mean I can mount in the accumulator position under the car and the FPR / fuel filter in the stock pump location giving me plenty of room. Using nylon style quick connect fittings.



 

Looking good as always

I like the swirl pot, where did you get that?, and how does it work with wiring seal, since i supposed that pot will be full of petrol ?
 And you still needs the lift pump in the tank.

Wonder if it could be made simpler  

and is it possible to form the hard plastic lines, that way it could be nice, I made mine in AN line and cobber pipe from back to front.

what is your plan regarding map ? Do you have a connection that can disabled your IMMO, and code the post-cat 02's out etc. ?? Looking forward to see it drive.

Does the engine come from a manual or DSG gearbox ?

Hummel said

Looking good as always I like the swirl pot, where did you get that?, and how does it work with wiring seal, since i supposed that pot will be full of petrol ?
 And you still needs the lift pump in the tank.

Wonder if it could be made simpler  and is it possible to form the hard plastic lines, that way it could be nice, I made mine in AN line and cobber pipe from back to front.

The fuel pump fits like this so the wires are on the outside. Surge tank was £36 from China  
This is the tool I'm using to form the lines:

 

Hummel said

what is your plan regarding map ? Do you have a connection that can disabled your IMMO, and code the post-cat 02's out etc. ?? Looking forward to see it drive.

Does the engine come from a manual or DSG gearbox ?

Vince at stealth racing has removed the immobiliser and will remove the post cat, VSS and any gearbox related codes when I drive up to him.

Mine had a DSG box but he said the car should work fine under 4000rpm.

I really want a picture on how your fuel system setup gonna be

Mine also had DSG and with my current file I'm having a non smooth torque curve, so I might need a expert handling my maps   .

when you drive it up to him he will re map on dyno. right?

and then we need numbers!