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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Sat Apr 08, 2017 12:58 pm 
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Location: Napier
It's been a while and the to do list keeps growing. I managed to tow the car to my current residence so it is much easier to get the work done. 300kms later and it now resides in Wellington. As I do not have a garage here for storage, I am working in the same conditions that many fellow Aussies do, outside on the driveway :D

After sorting out the leaking front seal, finding a broken engine mount, finding multiple other small leaks, replacing the rocker cover gasket and putting it all back together again, it might be running in another few weeks.

Just waiting on the engine mount from Craig at SPR. (1600GTI)

Still need to do a coolant flush but it has new oil in engine and gearbox.

Noticed one of the cam seals had walked out from its mounting due to it being so hard. Will have to replace it when new cams arrive.

The car had an issue a long time ago with it missing and at the time we found water in the spark plugs. My Dad put some of that stop leak gunk in the water system and it has been fine ever since, suspected crack in the head. While replacing the rocker cover gasket, I noticed the frost plugs had lots of corrosion around them and one bolt had rusted out and snapped in the head :cry: so new frost plugs will need to be installed.

Keep seeing a really small oil seep (not as big as a leak, but more than a weep), possibly from the dizzy and there is continually oil running down the gearbox and dripping off the bottom of the bell-housing. Many years of road grime to clean off to track down properly.

My thanks to Tassie_Mk1 for the imminent arrival of some trim that has been missing for a while.


Attachments:
File comment: Gearbox sump grub screw. Some nice person used vice grips at some stage, plus metal shavings in the thread! Oh dear.
IMAG1960.jpg
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File comment: Rust inspection and realigning the driver door.
IMAG1831.jpg
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File comment: Broken drivers side engine mount.
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File comment: Stopped for a break at the halfway mark.
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File comment: The car dolly.
IMAG1881.jpg
IMAG1881.jpg [ 844.15 KiB | Viewed 195 times ]
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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Sat Mar 10, 2018 12:51 pm 
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Joined: Mon Oct 12, 2015 11:30 am
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Location: Napier
So it has been a long time since an update and in that time the following has happened:

Moved 300km back "home" again
Fixed engine mount
Sourced some spare sparts
Fixed all oil leaks


As it has been sitting for some time I decided to take it around the block a few times to stop the tyres going square and to keel things ticking over.
All was going well, pulled into the service station to check tyre pressures, noticed it was leaking water (it was only a matter of time....).

Was checking out where the leak was coming from when the engine started hunting, before I could reach over to open the throttle it stalled, leaving me stranded as the battery was flat (had jumpstarted it to go for a drive).

Walked around to turn the key off and smoke was pouring out of the steering column. After further inspection I noticed that the high beam circuit was on and the relay clicked rapidly when turned on again.
Joy, more problems to fix. I was going to replace the radiator anyway as it is original and badly corroded.

In the meantime, I have spotted another red Mk1 around here in excellent condition, one elderly lady driver :)
Project is slow at the moment while I get the trusty Hiace back on the road, plus business plans etc.

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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Sat Mar 10, 2018 10:40 pm 
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Joined: Mon Dec 19, 2016 10:40 am
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Location: NZ
It's an ongoing love affair I guess...wish I knew why I was pouring truckloads into this suzuki...but I guess in the end it's because it's not easy....honduh=easy....suzuki=satisfaction.

Keep going mate. Come down some time and meet up
Cheers G


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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Fri Mar 30, 2018 2:20 pm 
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Had some spare time today seeing as it is Easter and I wanted to locate the source of the previous electrical smell.

Pulled the steering column apart and checked the ignition switch, bingo! Smells right toasty. Even managed to source a new one, what joy!

More parts on the way....


Attachments:
File comment: Someone's nice soldering job when they added a switched power supply...
IMAG2343.jpg
IMAG2343.jpg [ 1.12 MiB | Viewed 121 times ]

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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Fri Mar 30, 2018 3:52 pm 
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Location: NZ
8-[ looks like someone has been in there before ?


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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Sat Mar 31, 2018 2:27 pm 
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Yeap, for sure. A long time ago, not sure how long. Many years I expect as the guy who owned it previously was a chef and had no mechanical/electrical inclination what so ever.

Ah well, new parts ordered and should be fine for another 30 years!

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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Thu Jul 12, 2018 7:23 pm 
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Small update - I managed to find some time on a sunny Sunday afternoon and I managed to fit and test the new ignition switch. A quick cross-reference with the old one to make sure the wires were around the right way (as it was from a Jimny and good thing I did!) and it went in sweet as.

Also managed to discover another GTi being wrecked down south and secured the knackered rear wing and the side mirrors that I was missing, swapped over the mirror unit into my housing and its functional again!

New CV joints purchased so it now awaiting some more free time so I can lift the front end and replace those. Might be back on the road soon...

Does anyone have any tips for foam spoiler repair? I was just going to glue it closed enough to get the shape and have someone make a mold to make a fiberglass version, rather than the heavier foam. Would there be interest in the original spoiler design?


Attachments:
File comment: New ignition switch
IMAG2511.jpg
IMAG2511.jpg [ 1.17 MiB | Viewed 75 times ]
File comment: New glass
IMAG2510.jpg
IMAG2510.jpg [ 1.78 MiB | Viewed 57 times ]

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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Wed Sep 19, 2018 8:41 pm 
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Just a little update, fitted a new clutch cable. Whoop! Super smooth now.

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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Wed Sep 19, 2018 9:17 pm 
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Yes made a big dif here too Michael!


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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Wed Oct 24, 2018 7:46 pm 
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Location: Napier
So it has been a productive week or 3. It all started with an "I think I'll just do this...." and it turned into some rather late nights.

Installed new outer CV Joints. While removing passenger side (gearbox) also found the inner boot split, so it was a quick run to Supercheap for a boot kit before they closed.
Some fun and messy stuff later, she has new knuckles.

That lead on to get new brake pads. When you get the last pair of brake pads at BNT that have been on the shelf for a few years.... they are cheap :D

Moving onto installing poly bushes in the front suspension. I can see that it will make a difference in how she handles, although for some reason I do not have the sway bar mounts I thought I did. Just got the lower control arms in, they are a tight fit!

It is getting closer to getting on the road, now I have the rear drums to do. (I have recently done the drums on the mighty Hiace, so not really looking forward to it)

The more I work on this old girl, the more I wish I could steam clean the underneath of it all. It's a mess!


Attachments:
File comment: More meat. There was not much left on the old ones!
IMAG2692.jpg
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File comment: Drivers side
IMAG2691.jpg
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File comment: Passengers side. Found inner boot split too.
IMAG2693.jpg
IMAG2693.jpg [ 729.14 KiB | Viewed 40 times ]

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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Wed Oct 24, 2018 7:55 pm 
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Nice one Michael! Be good to see it run


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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Sat Oct 27, 2018 4:11 pm 
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It will be. Needs a new radiator, so waiting for the car fund to fill again before the next stage. Hopefully not too long.

Then off for a warrant to see what else I missed.

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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Mon Oct 29, 2018 2:28 am 
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The suspension bushes made a huge difference for us but then half of the rubber ones were buggered too


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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Sun Dec 16, 2018 3:50 pm 
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Location: Napier
It moved!

I wanted to see where this leak was in the cooling system and ended up getting more than I bargained for.

The poor girl had not been started for 6 months or so. Connected charge battery, turned over twice and fired. Running on fuel that is so old but still started first pop.

Traced leak to lower radiator connection, still not 100% certain if connection or crack in tank. Drove it slowly around the corner to the gas station to check tyre pressures. Back in the driveway water was leaking from rear of engine. That's new! Traced fault to solid hose leading to cold start valve. Off to Supercheap.

Wasn't planning on it but it got a wash and a clean out.

Moving on to replacing all the rear bushes with the poly ones, fixing up the air intake.

BTW, Lucus Oil Stabiliser is the ducks nuts. I put it in the van which was always hard cranking when cold. Turns over much easier. Highly recommend this product.

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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Sun Dec 16, 2018 8:00 pm 
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Carried on doing more work (as you do) and pulled out the radiator to find the source of the leak. Looks like it's from the seal on the lower tank, so I'll just get a new one. Having only had water in the system for a few years, there was quite a bit of rusty water so it will need a few flushes to get it all out I think.

While rad was out, there was easy access to front gearbox mount so decided to change that over as I have a complete set of poly ones. Not too tricky.
The original that I pulled out looks to be poly as well, just a softer compound. Guess the engineers knew something back then :)



Pics added, had to resize...


Attachments:
File comment: Front gearbox mount
IMAG2852-1125x2000.jpg
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File comment: Best stuff ever
IMAG2851-1125x2000.jpg
IMAG2851-1125x2000.jpg [ 375.76 KiB | Viewed 29 times ]
File comment: All clean
IMAG2850-1125x2000.jpg
IMAG2850-1125x2000.jpg [ 954.27 KiB | Viewed 30 times ]

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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Sun Dec 16, 2018 8:23 pm 
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Looking great Michael! Nice to have it running ay?


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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Tue Dec 18, 2018 5:45 am 
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Joined: Mon Oct 12, 2015 11:30 am
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Location: Napier
It was very nice that she started first pop.

It has been the case that it had always run, just something else pops up that needs fixing, might be a small hose, might be a CV joint, but that's the way of a car that's older than me.

I can also hear something grating in the rear wheels, probably a stuck brake pad, but I have all the parts to do the rear brakes anyway.

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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Sat Dec 22, 2018 7:46 pm 
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Guys, I'd like an opinion! Looking through the set of poly bushes I purchased some time ago and I have a set for the "rear control arm" and I was quite sure there was not one. Sure enough, no such thing on the car, however, there are these mount location that look like the right place for these bushes to go, if there was a control arm on the car. What are your thoughts? (I know shes dirty.....)

Another afternoon/evening, with more work completed.

Removed thermostat from the housing, yeap needs replacement. Go figure.
Decided to install rear gearbox mount with nice poly mount. Rear mount was broken, go figure.

Off to BNT next week for new parts :D


Attachments:
File comment: Old rear gearbox mount and the new one :D
IMAG2865.jpg
IMAG2865.jpg [ 575.2 KiB | Viewed 29 times ]
File comment: Top left shows mount location
IMAG2864.jpg
IMAG2864.jpg [ 575.05 KiB | Viewed 29 times ]

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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Sun Dec 23, 2018 10:30 am 
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Location: NZ
Wish I could help mate but boy the mark 1 is different!


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 Post subject: Re: '86 Mk1 GTI AA33S rebuild in NZ
PostPosted: Sun Dec 23, 2018 12:27 pm 
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Location: Napier
I'll get it down to Palmy soon (haha I keep saying that) and you can put it on the hoist for a gander, it is very different.

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