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81
Technical / Re: rev counter issue
Last post by Monkey -
As above, when I restored my red one, I had to swap out the injectors for a similar problem.
Also, go back to basics, check fuel and spark.
I'd pull the plugs out, then turn it over and make sure you have spark.
Then put them back in (dry), take off the coil lead and try turn over again, pull out all the plugs and make sure they're all wet, that'll account for fuel. If you have plenty of both, it's either mixture, or timing.
82
Members' Cars / Re: G135EPB 8v GTI
Last post by ianmac86 -
I took it for its MOT on 20/9/25 as it had ran out for the 1st time since my ownership. Glad to say it passed with no advisories  :)


I only drove it too and from the garage about 8 miles all in but car drove fine. Coolant needs topping up which i really hope is just some air left in the system!

Later in the week I decided i was going to get ready for the Quaife to be fitted. So back in the air and gearbox off. Although its been in and out more time than i care to remember, I've never done it alone. Mainly due to a lack of confidence and the gravel driveway. I felt that it needed to be done at home so I'm not leaving it somewhere other than my own driveway to remove the need to get it back driving asap. I was amazed the time i took the first photo with the bonnet up and to the time i took the photo with the box on the floor was 1hr 20 mins. The hardest part was lifting the box at enough of an angle to get the cup over the flywheel. I have to admit when the box came down onto my chest i got myself a bit stuck 😂 the weight combined with the car sitting fairly low to the ground meant i didn't have much room to actually get myself out from under the car. After a short struggle I freed myself and dragged the box out- had to remove the splitter for it to come out the front!
Started 11:50

Finished 13:10

There was 1 casualty - gearbox bracket collared bolt m8x92 which i need to get hold of a spare if anyone has one?


As i had some free time I decided to fit the missing flaps of the fan cowl and my new Febi fan. I know the cowling needs a paint but this is way down the list of priories at the minute!



Also picked up an induction kit for noises! I'm not sure if i will keep it yet but it's a bit of fun. Its meant for a mk4 golf with an 80mm maf. I've trimmed down the heatshield and used the off cut to make a temporary bracket to secure it the the chassis leg and removed the lower blank to allow some more cold air through. I've got a cleaning set from Rami Air so will do that when i get the opportunity. the ABF intake is 70mm so fitted and 80>70mm reducer and some alli pipe to join them together. The intake temp sensor has been mounted to the heatshield for now. I still need to trim the pipe down but i might see about replacing the whole intake with 90 degree silicone elbow for a nicer look but so will hold on for now.






At the weekend i'm hoping to rip the old 02a apart to remove the Quaife ATB and maybe take the new 02j apart to ready to remove the diff rivets from the crown wheel (horrible job). I've got new diff bearings as well. All of this is best done with some help if i ever want it to work again! So going to rope in Dan, hopefully for guidance more than just taking all of his spare time.
83
Technical / Re: rev counter issue
Last post by scs -
I have very slowly progressing a similar fault. Tried lots of items new blue sensor new fuel pressure regulator new plugs. Spayed brake cleaner on all the vacuum lines . No improvement by now running low on fuel new fuel problem virtually disappeared still a bit temperamental but loads better I now think the injection nozzles might be a bit clogged as its occasionally cutting out when the revs drop to tick over usually its fine drops to 900rpm but not always but restarts straight away.
86
I.C.E & Electrical / Best Coil and Lead Replacement?
Last post by Martin109 -
I have a 1990 Mk2 Driver (1.6 petrol) and the coil is on its way out; I had a breakdown and thought it was the electric fuel pump (having had one fail previously), but the AA man identifed immediately (duh!) a loose coil lead, which he said was caused by the coil beginning to leak oil and thereby affecting the plug on the lead.  He zip-wired it in place and the engine started immediately.

Which all leads to my question – what’s the best quality coil and coil lead for my vehicle?  Someone suggested a sports one as high quality, but the man at Merlin Motorsport said best to go with VW (meaning Bosch presumably).

Very grateful for any suggestions.
90
Members' Cars / Re: G135EPB 8v GTI
Last post by ianmac86 -
This was the state of my heater matrix when it came out:


The foam flaps I replaced about 10 years ago haven’t held up too well although the clouds of steam probably didn’t help!



I wrapped the edges with foil tape for extra stickiness (and because I may have accidentally ordered non-sticky foam…).



Went for a Mahle matrix  decent brand and hopefully means I won’t be doing this job again any time soon!


Perfect chance to flush out the rest of the pipework too – the grime that came out was disgusting. Not what you want blowing into the car.


All back together:


Cleaned the remaining ducting with the pressure washer while it was out.


Carpet dried and wrestled back in. I still hate refitting the foot rest!



Collected the cylinder head from Knights:




Started the rebuild. Lapping the valves was tedious and my hands weren’t thanking me either! I got some help from Dan as i hadnt done any of this before and was highly likley to do something wrong unsupervised!


Cams and chain back in. Vintage cutting paste I dug out of my dad’s old toolbox.



Made a bit of an impulse buy . I’ve wanted a set of these for ages but refused to pay new prices. Found a bargain set from a really nice chap in Rugby who used to race in the Teekay Mk2 Cup and was selling off spares. I couldn’t say no.



Back on the engine – blasted the head bolt threads out with compressed air to prevent hydro-locking when torquing down. Glad someone mentioned this, as they were full of oily coolant or coolantly oil.


New expansion tank and cap. The old cap didn't releasing pressure when the matrix went?


Block face cleaned up:



With kids and dogs constantly distracting me, I wrote down each head bolt tightening step to keep track of the sequence.


Head torqued up:


Timed up:



Rocker cover back on – fingers crossed for no leaks this time, it’s given me grief in the past.


Exhaust manifold back on. This was more of a fight than expected – ended up supporting the exhaust with blocks of wood to get the manifold lined up.



Collected the wheels from powder coat and had new tyres fitted. Went for gloss black with Accelera 651 Sport – I ran them on the Sebrings before and they were great for the price. Not AR1 or R888R level, but half the cost, so no complaints.

Test fit:


Cleaned, ceramic coated, and new centre caps fitted:



Had to wait for the stud and taper nut conversion. Annoyingly, the studs only came with 19mm nuts, which makes it tricky to get a socket on without risking the fresh powder coat. Ordered a spare breaker bar and thin wall 19mm socket for the boot, plus a set of radius nuts for the spare wheel.


One side done – wasn’t sure at first, but they’ve really grown on me.





Saw this on Facebook – type in a certain command with a photo of your car and it spits out a toy version. Couldn’t resist.


Back to the engine again. Started bolting things back on before I forgot what went where. Even managed to get the heat shield on (needed a bit of trimming to fit with the 4-1 Milltek).


Stopped taking photos at this point, but basically got the rest bolted up, timing belt back on (was only 12 months old) replaced oil and filter, then cranked it without the coil lead to build pressure.

Good news: no leaks, ran up to temperature, and fans kicked in! The fan itself wasn’t happy though – catching on the cowling. I’ve ordered a new OE unit anyway as it didn't sound too happy either. Briefly looked at 2x 10" slim-line aftermarket fans but the wattage/CFM ratings were down on OE, especially without the cowling.

A few jobs left todo:
MOT runs out 18/9/25
Test drive
Replace Oil and filter after a few hundred miles
I want to re fit the Powerflex topmounts after trimming them down a touch
Needs more camber adding so probably refit camber bolts and try my new alignment gauges
I really want to get the Quaife fitted to the new gearbox

Hopefully then i w ill have a good car to enjoy... over the winter! 😂