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21
Members' Cars / Re: G135EPB 8v GTI
Last post by ianmac86 -
A couple of steps closer last night.
A big puller was borrowed to get the gears apart so we could reach the bearing near the bottom of the gear stack. I didn’t think it was going to come apart, but after applying a bit of heat it suddenly popped — scared the living poo out of me 😂

Next job was to clean this all up and not cock the order up!


Ran out of time again, but despite there being no photos, it’s now back in one piece. The box is basically ready to be rebuilt properly, apart from one bearing in the casing that still hasn’t been done yet.
I doubt I’ll get the chance to finish it over the weekend, or even next week, so for now I just need to sit patiently and wait for some spare time that lines up with Dan as well so we can get it finished off.
24
Engine & Gearbox / Golf Driver 1600cc 1990 carburator top cover ( airbox)
Last post by philip -
Hi, I'm new and this is my first post :)
I have a 1990 mk2 golf driver 1600cc cab 55 Kw EZ 75HP , just before the 1800cc came out.
I've been doing my head in about 2 little things and hope someone can confirm, TY.

First, on the plastic cover that fits on top of the cab, mine doesn't have a round joint in between the part that fits on carburetor ( round). Is this normal ? i made loads of research and seems it doesn't have one from factory and usually is for 1.1-1.3 models only ?

Second the air filter housing secure rubber at the begining of the hole airfilter box is broken and i'm lookimg everywhere for a replacement. This model has one that only screws on one side and then the other side is a metal curved ring that fits and holds on the airbox ring. All i could find is the standart one with two threads that of course will not fit ! Any ideas where i can buy this ?

Thank you for all your advices,

Phil.
25
New Members Say Hi! / Newbie Here – My Volkswagen Passat
Last post by onghyr -
Hi everyone, I’m a newbie in the group and wanted to introduce myself along with the car I was lucky enough to get recently. I just picked up a Volkswagen Passat (B2) (Passat Mk2) in excellent condition. It’s powered by a 2.0 16v engine from 1982, and it has been upgraded to around 500 horsepower.
I’m really excited about this car and looking forward to learning more from everyone here about maintenance, upgrades, and everything related to the **Volkswagen Passat. Glad to join the community and share the passion
28
Engine & Gearbox / Re: 1991 1.6 Driver - Weber 32/34
Last post by Keekster64 -
Quote from: merlinuk on
In the image I posted, I showed where the metal mount meets the manifold with the rubber on top of that. The rubber looks OK but the mount is very badly split and warped. Upon searching for replacement mounts I couldn't find one that looks like my broken one, So I referred to the image of a brand new Weber 32/34 MK2 kit and the mount that I'm supposed to have looks nothing like mine... just a £90 replacement  :-[
The part that is split in that photo, is the rubber mount.  The rubber mount bolts straight onto the inlet manifold.  It looks like someone has painted over the bottom half of the rubber mount, presumably to paint the manifold.  Once you remove the carb you will be able to see it properly.  I recommend the Febi rubber mount, as it puts up with the ethanol in modern fuel better.  However, I dont think its the cause of your idle issue.
29
Engine & Gearbox / Re: 1991 1.6 Driver - Weber 32/34
Last post by merlinuk -
In the image I posted, I showed where the metal mount meets the manifold with the rubber on top of that. The rubber looks OK but the mount is very badly split and warped. Upon searching for replacement mounts I couldn't find one that looks like my broken one, So I referred to the image of a brand new Weber 32/34 MK2 kit and the mount that I'm supposed to have looks nothing like mine... just a £90 replacement  :-[
30
Members' Cars / Re: G135EPB 8v GTI
Last post by ianmac86 -
I swapped the pump over the other day. I was hoping to see something visably wrong with the old one but other than looking old it appears ok. I did notice the breather pipe was blocked with a bolt so this needs routing correctly.


Here is the new an old pumps side by side. I might of just wasted £70 here but i'm willing to take my chances! I will hang on to the old pump for now, if my fuel issue disappears i can refit old pump to see if it returns to pinpoint the issue.


New pump in. The old clips seemed impossible to redo up so i've fitted some jubilees but will get some replacements.


i got some connectors and loom off another mk3 hoping to use to replace some of the wiring that goes to my throttle body switch and other wiring that goes past the exhaust manifold. I ordered a de-pinning tool and practiced on the off cuts and seemed pretty easy to use.


I looked at de-pinning the loom on the car but i could see this getting out of hand very quickly! So decided to cut away the damaged crispiness and join them and see how that goes

heat shrinked

and doubled insulated

i taped the loom back together and wrapped some heat resistant sheathing over to give some sort of protection

i over ordered on this as scaled price made better sense so wrapped it over the brake pipes also. there is some excess so may as well put some over the clutch line too. Probably overkill but better that nothing?


Went back round to Dan's to start replacing some bearings in the gearbox.
Some of the old bearings




Started by replacing the easier ones on the casing



We couldn't find the right puller so had to leave it there for now but hoping to get the rest of the bearing done and all built backup before the weekend so i can refit and test!