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Topic: Gordon the Golf (8v GTi 1989) (Read 24532 times) previous topic - next topic

Re: Gordon the Golf (8v GTi 1989)

Reply #240 –
Is it really 2 months since I progressed Gordon?  If I don't get a move on he won't be seeing action this year.
He had a welcome back surprise for me; a coolant leak from up the back of the engine.  I've pressure tested the system and there is a leak from the radiator top hose at the cylinder head flange but I can't see how the coolant gets from there to the back of the engine?  Any ideas?



Now getting on with the painful job of bending brake pipes.  I have OEM bends in pictures for all pipes (shown in service manuals etc) except this one, shown here is yesterday's efforts. 

 

Not happy with it though, it gets a bit close to the floor pan and could trap air.  Anybody still got OEM pipes and got a picture?  Thanks.

Re: Gordon the Golf (8v GTi 1989)

Reply #241 –
I had a leak on mine from that flange and it made such a mess. It would puddle on top on the gearbox and then drip down off the bottom of bell housing. Has the coolant crystallised? Should leave you a path back to the leak as proof?

Re: Gordon the Golf (8v GTi 1989)

Reply #242 –
Bugger about the coolant leak, as Ian said, it usually tracks around/through where the gearbox meets the block.

I too have been doing brake lines this weekend, think I have the original one of those, if I recall, it's just a 'C' shape.
I'm down the workshop this week, I'll grab a photo for you.
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Re: Gordon the Golf (8v GTi 1989)

Reply #243 –
Not had access to the PC this week, my wife is studying.  As a result though made quite a bit of progress with Gordon;

All brake pipes on
Heat shields on
Exhaust on
Rear axle on

I'll have to get some pictures today.

After a Facebook debate I settled on the following pipe bends:



The only coolant leak I found was caused by mould flash:



Cleaned it up and fixed the leak but I still have coolant under the car.
 


I don't know where it is coming from, can't find another leak anywhere.

Re: Gordon the Golf (8v GTi 1989)

Reply #244 –
I was going to scrap my fuel tank because the filler earth had rotted away.  I visited MK2 Spares and discovered that every 30 year old tank is rotted at this earth.
So I got my soldering kit out.  It would be neater is I was doing the job a second time, but I'm pleased with this:



Probably on for my first start in 5 years next week :-)

Re: Gordon the Golf (8v GTi 1989)

Reply #245 –
Nice repair 👍🏻 goodluck with starting it up, hopefully that coolant leak is sorted too 🤞🏻

Re: Gordon the Golf (8v GTi 1989)

Reply #246 –
Fitted the fuel tank today, checked the immobiliser and turned the key. Nothing, if I turned it further it would crank the engine. Nothing from either fuel pump. Ah well back tomorrow with a multimeter. Interestingly the fuel gage responded.
What I can’t find is a PB engine fuel pump wiring diagram.
Anybody got one?

Re: Gordon the Golf (8v GTi 1989)

Reply #247 –
When you turned the key, did the lights come up on the dash?
Mk2 Driver
Mk2 Silver 8v
Corrado G60 Turbo
Mk2 Red 8v
Mk2 Grey 16v
Mk2 BBM ABF
Bora 20vt
Mk2 Green VR6
Mk2 Green ABF
Mk2 BBM 20vt
3.2 TT Roadster
Mk2 Red 16v
225 TT Coup
3.2 TT Coup
Mk4 Anniversary
Mk7 Red GTI Performance
Mk2 Red GTI Restoration
Mk2 BBM R32
911 Carrera 4S

Re: Gordon the Golf (8v GTi 1989)

Reply #248 –
@Monkey yes everything came up.  Been back with a multimeter.  No voltage at the pumps, earth was fine, traced the problem back to the fuse box.  I don't know how this can happen but the fuse was good but no current passed it.  Unplugged it, plugged it back in and both pumps came to life.  After cycling the pumps several times fuel arrived at the fuel rail, bled 1/4 liter to get any muck out.
I changed the oil. switched the fuel off and cranked for oil pressure.  Fuel back on and:

https://youtu.be/trWR08e3ITs

Got it up to temperature, thermostat opened fine, radiator fan fired up.  Heater was volcanic.  Slight leak from the diff drain plug but looks dry elsewhere, oil, fuel and coolant appear good.  Goes through the gears OK.  Brakes, paint correction and setting up of engine and steering geometry over the next few weeks then it is MOT time.

Re: Gordon the Golf (8v GTi 1989)

Reply #249 –
Happy days, glad it was a nice easy fix.
Mk2 Driver
Mk2 Silver 8v
Corrado G60 Turbo
Mk2 Red 8v
Mk2 Grey 16v
Mk2 BBM ABF
Bora 20vt
Mk2 Green VR6
Mk2 Green ABF
Mk2 BBM 20vt
3.2 TT Roadster
Mk2 Red 16v
225 TT Coup
3.2 TT Coup
Mk4 Anniversary
Mk7 Red GTI Performance
Mk2 Red GTI Restoration
Mk2 BBM R32
911 Carrera 4S
 

Re: Gordon the Golf (8v GTi 1989)

Reply #250 –
Seems like this is getting really near, its good to hear it running too 👍🏻

Re: Gordon the Golf (8v GTi 1989)

Reply #251 –
Quote from: ianmac86 on
Seems like this is getting really near, its good to hear it running too 👍🏻
Thank you, when it started it sounded like somebody was hitting an oil drum with a big hammer. I only recorded it idling when I convinced myself it was normal.
I've had the very same hydraulic tappets on two diesel engines that together clocked 400k miles.  It is amasing how diesel knock hides tappet rattle.  Petrol engines are very quiet by comparison.

Re: Gordon the Golf (8v GTi 1989)

Reply #252 –
Today I paint corrected the boot floor pan.  To claim to have corrected it it is a bit of an over statement but it did end up quite shiny.  Just checking the tools and compounds for the shell.  May get pictures tomorrow.

Re: Gordon the Golf (8v GTi 1989)

Reply #253 –
A couple of days ago I decided to tidy up the boot so that I could store the car cover and make a start on paint correction.  I'm still at it!  Treating a small number of minor rust spots and repairing this;



Probably the least fit for purpose part on a MK2 over the years it has been broken repeatedly while removing shopping and as a fix at some time in the past it was glued to the car with black silicone.  I've made missing bits out of a ready meal food container and strengthened the underside with black Gorilla tape.
The interesting thing is I feel that repairs like this detract from the originality of the car, like also the fiberglass reinforced heat shields or the wrong but superior design bungs in the floor pan.  Do I call the car original or restored?  Edit or maintained?

Re: Gordon the Golf (8v GTi 1989)

Reply #254 –
This is how the boot turned out.  VW weren't exactly careful with the paint, I've managed to retain that uneven factory look:



I was checking out my tools and compounds for a much bigger job.  This is the O/S c-post:



My efforts won't be quite as good as a pro but I'll very much improve on that.  I've got 32 years of care scratches over the whole car, I think it will take about a week to sort it.