MY G Reg Jetta GTI 16v mk2.. Well new for me

Last edited by on Wed Dec 12, 2007 12:33 am; edited 1 time in total

cheers mate, recieved the VW window wednesday night, but still waiting on the pipe its on backorder from germany. might be months, cant start the damn thing without it either!

still hopefully at the weekend ill be able to find a piece of pipe for bodging untill the proper pipe arrives.

been on the phone to C&R as the manifold is possibly blowing so might be gettint a polished ported manifold and stainless exaust sytem, want something very oem looking tho, nothing lary or loud.

also might be getting some ARB's as i want to improove the handeling.

will keep you all updated as soon as i do more Very Happy

well the cars been in over the weekend and monday, to try to figure out why it runs so lumpily, the emmissions were off the chart when it got there, turned out the metering head was shot

swapped it from my other jetta, and instantly it ran flawlessly, managed to pic up another one for £40 from a friend so now the car seems to be running fine gears and engine, time to turn my attention to brakes and suspension, hopefully gonna order some VR6 pads for my calipers tommorrow and maybe make a start on fitting all the new calipers and maybe the new master cylinder i have. also gonna wack the rear struts off as theyre sagging and fit some i have in the shed that are solid, should make it look nice and level, and not tired

in the end had to fabricate a pipe for the missing part so i could drive the car.

got a bill of £166 from the garage :S but id have never have figured out it was the metering head so i suppose it was worth it.

also bought a brand new battery for it.

might also swap over the radiators, and if i feel up to it swap the water pumps too

also wanna get the fog lamp changed over and maybe even the headlights and slam panel have the rest of the week off, so should get quite a bit done, might start with the easy stuff tho and see how i get on with the brakes later lol

edit also could a mod move this topic to the members motors section? thanks

Admin Age : 27 Joined : 08 May 2007 Posts : 592

My goodness you are moving fast in getting it up to scratch - You ought to take some pics as you go when you do things and put it in the how to section Smile

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yesterday i took the rear struts off and did two trips to vw for parts, vr6 pads and rear pads, then a load of suspension stuff as half the washers and bits were missing. lol

here is how it started the day

you can just about see in the pic the rear is lower than the front, so i took the struts off to replace with some i have in the shed

got them off and oh dear

old strut on the bottom newer strut on the top

as you can see from this the old strut is much taller than the new one, so one of two things is going to happen

the car is gonna sit really low at the back, or the new stut even tho its smaller is going to sit higher because its harder and stronger....

its a standard 16v item so maybe the fronts are none gti height

if thats the case, might have to fit some suspension sooner than i thought. still it should be alot beter either way as what was on was really saggy, even a little weight in the back and it dropped down further, so should make it handel a little better too.

tommorrows job looks like an oil change, get the front bumper slam panel etc off and maybe swap water pumps and radiators over from both my cars. also might get the rear brakes off, but i think im ging to leave the brakes for another week as i dont want to have to take my current gi appart at the moment incase it takes me too long to put it all back together again lol plus its so low i can never get under it to get at the middle braided hoses anyway lol

todays progress,

first off took the bumper off needed to do this to get at the fog lamp

then i took the radiator off its really fecked! plus its a carb model one, so its huge!

water was very brown so ran some water through it a few times

then i took off the slam panel and what goes with it

noticed the crossmember thingy was a bit rusty

so i ground it down with a wire brush attachment for my drill, then painted it with "rust Roy" which is a kind of reactive mixture which reacts with rust and turns it and steel blue which then stops it from rusting, in theory anyway. lol, then you can paint over it with hamerite, which i will do after 24 hours for the roy to cure

found this radiator with the bits that came with the car, dunno if its any good but ill give it a try

looks a little tidyer now... and messier at the same time lol

so i went in search of my other set of fog lamps and found my new non genuine bumper bought about 4 years ago by tubthumped when he borrowed my big bumper and crashed it lol

so now i have to decide weather i want to keep my genuine one, or fit the none genuine one, would be no contest if my genuine one didnt have this...

genuine

none genuine

whichever i get i will fit the fogs i bought years ago, i thought the fogs that came with my car were fine untill i compared them

cars fogs

fogs i bought years ago

the ones i bought years ago had one fot where the connector was snapped off and some iffy wiring to get it to work, luckily tho the cracked fogs coneector was a straigh swap so the other one is as good as new now woo! lol

what do you think then? im swaying toward fitting the none genuine one for now seeing what it looks like and keeping the genuine one as a spare ?

hopefully tommorrow my brake pads and suspension parts will come from vw so i can get it all back together at the back, ill paint the crossmember with black hammerite, ill take the rallye grill of my car fit the jetta front end to it take the realy loom off it and fit it into place on my new car, and if the paint dried maybe start fittin the front end backtogether on the new car, also might take the rear bumper off and swap the skins over, car will have all odd coloured bumpers for a while but hopefully not for too long, once its all on there is only the brakes to look at, but might get an mot before i look into that, then i can tax it swap my insurance which will make it easier but i think it will still be a couple of weeks

wish me luck, no doubt some more pictures tommorow

edit:forgot to add, also did an oil change today with some fresh vw oil as i was advised to as the car had been spitting out unburnt fuel when it wasnt running right, which could have mixd with the oil, so thought i may aswell, so another thing to cross off my list!

Admin Age : 27 Joined : 08 May 2007 Posts : 592

God what a task!

The suspension is interesting though, so the new shocks I had fitted were not 16v one's, is that right? The back I tried to do myself and failed so took it to John Noble Motorsport - so either they lost all the bits or they weren't there to start off with?

Either way, the on going report is fascinating!
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looks that way andy, eithr that or they are gti 8v ones not sure if they were as low as the 16v, and the rear socks were shat anyway so i dont know if you bought these new?

ive fitted bose turbos which i believe are stock 16v one to the rear, might look into how much they are for the front if it looks too daft, just got it all back on the ground and doesnt look too bad at the mo, but might sink a little when i drive it around a bit.

just popped on here to remind myself what else i have to do and to let the crossmember dry after the third coat lol.

will post up some more pics later

well not a massive amount of progress today, got my suspension bits and pads form VW, so refitted the struts with the new parts, and yes the car now looks like its on stilts at the front lol!!

here they are on

and heres the crossmember sprayed up this was about the first or second coat, and put 6 on in the end, will take another pic tommrorw looks really good tho to say its just going to be covered up lol

also picked up a radiator fan loom and put my other car on ramps ready for the front end swap tommorow.

looks like im going to be driving my sisters for ka tonight lol! speed machine!

steve im loving your detailed work in progress,i always forget and do the jobs then take pics after,but yours is really interesting,GOOD JOB THAT MAN;)

well i always find that when i read threads about peoples cars i always find them way more interesting when they have a lot of pics to look through so i thought id do a thread the same.

cheers vardo, hopefully will be more tommorrow!

Im lovin it mate the work in progress report is superb
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Hate this cold dark time of year, car has sat there for two weeks now without being touched and i cant get enough light or warmth to get back into it, however i ordered a few connectors for the headlight looms oem ones from vw so the loom will just click in and out should i need it to, which i have ready, and im going to order all the wires of tinterweb this week so the colour of the looms all match. then ill refit the front end.

at the moment im deciding weather to replace the thermostat and remove the bypass valves, then get the dash out and fit a new heater matrix while im at it all

hate the bypss valves there shite might see how much the none bypass hoses are to replace the valves instead of using copper

again another empty update, all ive done so far is worked on my hadlight loom. looking good butnot that interesting lol, still, will get my rallye grill back from the body shop any day now so hopefully will be something to report before too long!
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Right been doing a bit here and there over the last few weeks regarding wiring up my rallye grill wih new relays and stuff, most of the pics are about the wiring so pobably not all that interesting but here you go away.

so i decided i wanted to do the loom right and use all the proper connectors with no need for splicing wires together or soldering stuff on, just factory looking looms. I also wanted to get the wire colours as close to OEM as possible which was ok for some things but not for others.

so there are the connetors i got from VW:

i also had to buy all the crimps and connectors that go inside these. vw only did them with wiring preattached so you could solder the pre attahed wires to an existing loom etc which i didnt want as i wanted it to look perfect.

so i managed to get them online, the ones for the rallye connecors wernt cheap either lol!

so i put the connectors together with the correct wires to create the relay loom. the idea of the relay loom with the correct connecors is, i can clip my loom into place and if i ever remove it i can just un clip it. mainly because when i took my old loom out of my old car i had to cut things and solder things and it was a mess where as with this i can put it all back to standard in about 5 mins, also the wires are one length from the headlamps back to the relays as i got all the vw connectors and cripms no soldering or splicing was required, on my old loom i had to splice my relay wires to the origional connections which left parts of the loom with electrical tape wrapped around the connections and so on, this was messy and i wanted to avoid it Smile

Here are the connectors in place on the passanger side headlamp:

Drivers side:

How ive routed the wires:

and this is a closeup of the rallye connector, as you can see the wires go through a rubber seal right at the bottom of the connector to stop water getting in. however rallye headlamps dont have sidelights powerd through this connector they have a seperate connector (see above) and on this connector there is a hole for the side lamp wire, so i filled the side light hole with silicone sealent to stop water getting in. i also did this on the side light connectors as i didnt have any rubber seals for these. should stop the connections getting damp anyway! again look at the above pictures and you cann see where i have put the silicone sealent:

This is the relay holder:

pretty water proof and tidy.

This is the fuse box for it:

This is what is yet to be finished, i have left these wires full length so i can cut them to the correct size once on the car, these are the wires that will connect into the origional looms for the headlamps fog lamps and side lamps:

Here is the slampanel and headlamps i tried to run the wires as neatley as possible so they couldnt be seen from the front or above and they were tidy and out of the way

And finally here are some shots of the grill attached to the car, think it instantly gives the car a meaner and more modern look

obviously there is quite a bit to do yet to get the car back together, just wish this weather would ease up alittle when im off work ! sorry about the pictures here but the camera isnt so geat in the low light.

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had a day off today so heres Another boring wiring update lol

started with this

ended up with this

fuse holder

nice and neat

woo we have light!

was hopeing i was gonna have the front end back on today with radiator etc, but ran out of light at 4oclock so managed to get everything but the fog lamps wired up, maybe if the weathers nice on saturday i can finish it then
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