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 Post subject: Re: AWD GTI
PostPosted: Thu Apr 30, 2015 9:27 pm 
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Location: Adelaide
https://www.youtube.com/watch?v=93vq_8LUiTo

I apologize for the sound quality, it was a phone after all!

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 Post subject: Re: AWD GTI
PostPosted: Fri May 08, 2015 12:50 pm 
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Location: Londoninium
So fuel pump upgrade time.
had to strip the entire rear suspension and drivetrain out to get to the tank. had to cut a few of the factory hose clamps due to corrosion
at least its a nice and clean floor above the tank
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the tank is quite complex
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with three opening in the top. Delivery pump with its own internal sump, a lift pump to feed the delivery side which also includes the fuel gauge sender and a low level trigger for the supply side
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and the rear sub-frame seems to be surviving well since the rebuild
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The Justy pump is tiny compared to the GTi pump. its high pressure but obviously low volume. So a Walbro 255L replacement was quite an easy fit as its smaller diameter then the GTi pump so no adaption was necessary.
So hopefully it stays together as Its a day job to repair again if necessary.

GTP


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 Post subject: Re: AWD GTI
PostPosted: Fri May 08, 2015 12:57 pm 
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Joined: Thu Jun 09, 2005 11:16 pm
Posts: 3227
Location: Perth WA
Yea, I know the feeling, pull 80 parts off just to replace one underneath :lol:
Atleast you've now ruled out clamp failure down the track.
Looking good


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 Post subject: Re: AWD GTI
PostPosted: Sun May 17, 2015 6:14 pm 
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Posts: 2174
Location: Sunny Perth, West Australia
With my AWD I cut a nice access "hatch" above the fuel pump in the floor. First of all it avoided pulling the whole rear out and now if anything goes wrong, I can now access the pump from under the back seat. It would be very easy for you to do now you have stripped everything.

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 Post subject: Re: AWD GTI
PostPosted: Sun May 17, 2015 9:59 pm 
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Location: Londoninium
Thought about it but decided the nice clean floor will remain intact. This is not the cut-big-holes-car
Now its done with new jubilee clips and lubricated bolts its a bit easier , probably a 3-4 hour job. and if the new fuel pump fails the car is getting junked :twisted:!

GTP


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 Post subject: Re: AWD GTI
PostPosted: Wed May 27, 2015 6:21 pm 
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Joined: Mon Aug 25, 2003 12:00 am
Posts: 1526
Location: Londoninium
Slow going at the moment on this...don't ask about the race car.
New Baby at home means time spent on this is limited and the spend less project has my imagination at the moment...Oh and nothing seems easy.
Its all together, has run and made the cat glow orange. Addressed a few issues and now it pours fuel out the exhaust so need to trim a bit out of the E85 base map to get it to idle and run a bit cleaner before heading to the tuner.
But now the starter motor appears shot so Just ordered another one should see it in on the weekend...maybe!
Also awaiting some braided fuel line to convert to earls style fittings as I need to move the fuel lines as the air filter hits them in their standard position
A pretty blurry picture too
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GTP


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 Post subject: Re: AWD GTI
PostPosted: Mon Jun 08, 2015 9:56 pm 
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Posts: 1526
Location: Londoninium
slightly better phone photos this week.
ECU mount to straddle the gear change cables under the heater box
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with ecu mounted
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In place in front of airbag sensor
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Oil cooler, I think some better brackets are needed ultimately but will allow it to be tuned
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Engine shot 1 all plumbed and wired up. Had to cut and shorten the fuel supply and return pipes and run braided flex as the air filter hit them.
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and the throttle bodies, just need to rework the accelerator cable as it clashes with the filter as well. Once its all up and running and showing signs of reliability ( ie wont be swapping the old engine back in) Ill tend to the old engine wiring loom and strip it out.
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so also replaced the starter motor and the battery and it wont run!!!!!!! F*&^(*^&%(* it

GTP


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 Post subject: Re: AWD GTI
PostPosted: Sat Jun 27, 2015 8:35 pm 
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Posts: 1526
Location: Londoninium
So after another blown coil igniter I have converted it to 4 LS1 coils which meant rewiring the coil side of the loom. Then with Moyle19's gracious help this afternoon (thanks simon) we got it running and idling without huge plumes of unburnt fuel out the exhaust, just enough to burn the eyes. The ecu map is for E85 so is pretty rich for 98 premium.
Then I drove it out of the shed for the first time in months and discovered no brakes and loose front end...oh yeah forgot about that. plus a massive oil leak pressure side of the oil cooler so packed it away as it was too cold to lie under it to investigate the once slow but now severe oil leak. Brakes need remote reservoir plumbed in and bleeding. but most importantly it drives in both directions so once these things are fixed its to the dyno.

GTP


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 Post subject: Re: AWD GTI
PostPosted: Mon Jun 29, 2015 3:09 pm 
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Joined: Wed Feb 22, 2006 5:19 pm
Posts: 1975
Location: Launceston, Tasmania
Good to hear this is moving forward again. I can't wait to see it in action, it should be a real weapon!

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 Post subject: Re: AWD GTI
PostPosted: Mon Jun 29, 2015 7:58 pm 
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Posts: 1526
Location: Londoninium
Thanks Tassie. I cant believe how long and how much money it has cost given I 'had' everything...most of which needed replacing as it was wrong! don't believe everything you read on the internet. but its nearly there and so is the escort!

GTP


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 Post subject: Re: AWD GTI
PostPosted: Tue Jun 30, 2015 1:36 am 
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Joined: Thu Jun 09, 2005 11:16 pm
Posts: 3227
Location: Perth WA
I feel for ya.
Every day at work there's little setbacks, and that's working with bolt on factory gear,
Let alone teething a new custom install
:) keenly awaiting vid with good audio


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 Post subject: Re: AWD GTI
PostPosted: Tue Jun 30, 2015 1:47 pm 
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Posts: 1975
Location: Launceston, Tasmania
gtpswift wrote:
Thanks Tassie. I cant believe how long and how much money it has cost given I 'had' everything...most of which needed replacing as it was wrong! don't believe everything you read on the internet. but its nearly there and so is the escort!

GTP


Ha! Dont get me started on "having everything" :P it'll be worth it in the end (for both of us hopefully!) I'm really keent o see what sort of track times this puts up compared with similar 2wd GTi's, it should be very quick despite the extra weight and the extra grip should make up for the weight gain over a GTi I would have thoguht, plus it sounds mental! :mrgreen:

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 Post subject: Re: AWD GTI
PostPosted: Sun Jul 05, 2015 11:12 pm 
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Joined: Tue May 19, 2015 1:56 am
Posts: 16
Location: Chepstow - UK.
Hi,

Nice build - Where did you relocate the brake reservoir to? I'm looking at trying to move mine for the same reasons. I would be keen to see more pictures / more info on this!

Thanks

Chris


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 Post subject: Re: AWD GTI
PostPosted: Mon Jul 06, 2015 1:48 pm 
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Posts: 1526
Location: Londoninium
Ill tell you next week, when I work it out!

GTP


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 Post subject: Re: AWD GTI
PostPosted: Sat Jul 11, 2015 7:28 pm 
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Posts: 1526
Location: Londoninium
so bloody cold in the shed today.
Fitted these though
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well when I say fitted, took the clear lenses of the new bodies and installed with orange globe onto original bodies. the aftermarket ones are junk fitting and reflectance of lens.
and Im messing about with this trying to get the right ratio for the throttle movement
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found the oil leak and tested the air filter which is a tight fit against the bulkhead. then played around with brake master cylinder remote reservoir...no photos as I had no solution.

GTP


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 Post subject: Re: AWD GTI
PostPosted: Sat Jul 11, 2015 8:08 pm 
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Joined: Sat Mar 08, 2008 1:07 pm
Posts: 1065
Location: Western Australia
Hi gtp,

A quick question if I may?

I've noticed you are using SAMCO radiator hoses. I have the same set (albeit in black).

I've recently bought an AWD gearbox that hasn't been installed yet and was wondering how easy it was for you installing your hoses (?) Apparently there is a slightly differing cast joiner piece underneath the gearbox exclusive to AWD models...

Were there any issues of note that you had?

Cheers,

Drew

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 Post subject: Re: AWD GTI
PostPosted: Sat Jul 11, 2015 8:38 pm 
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Joined: Mon Aug 25, 2003 12:00 am
Posts: 1526
Location: Londoninium
Drew,
the only hose that fits is the top one, the rest are standard subazuki.
Typical.
GTP


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 Post subject: Re: AWD GTI
PostPosted: Sun Jul 19, 2015 11:03 pm 
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Posts: 1526
Location: Londoninium
fucking thing!
Why is the brake booster 25mm thicker than an australian delivered one, why is the master cylinder only 20mm diameter and 20mm longer with different brake pipe configurations
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But its getting there
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awaiting new remote reservoir then these holes can be plugged and maybe It can be driven more than 200meters
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GTP


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 Post subject: Re: AWD GTI
PostPosted: Sat Aug 01, 2015 9:51 pm 
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Posts: 1526
Location: Londoninium
sorted the brake remote reservoir today
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seems secure enough and should work fine
had the trumpets welded to a filter base, then I sand blasted it and polished the important parts up
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tested them in the bay and it fits!
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and started on the bracket for the throttle linkages.
had previously cut and tapped the throttle bodies for a mounting plate
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will trim this one up once the throttle cable stay is welded on, can see the start of it on there just ran out of day.
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.

GTP


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 Post subject: Re: AWD GTI
PostPosted: Sun Aug 02, 2015 8:32 pm 
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Joined: Thu Jun 18, 2009 9:56 pm
Posts: 2058
Location: Cessnock
Hey GTP, where did you end up sourcing the throttle linkages?

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