Ts' 1.6tx

I've already posted some pics of my TX in the members rides section but as it's about to become a bit more of a project I thought I'd start a thread in here. Hopefully I'll be able to keep it as a daily driver as I do the work .
I have to really, especially now my car share has gone down the tube with my 'car sharer' getting himself a new job! I can use my wifes' car during the summer holidays so I have some slack.
As I bought it:
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With the help of these:
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I got it a bit lower and fitted gti discs with new calipers
before and after
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Hopefully over the next month I'll be fitting a weber and GTi cam.
I'm keeping my eye out for a GTi dizzy as well but funds are a bit short at the minute.
First thing I'm going to do is rig up a narrowband air/fuel meter so I can monitor the mix as I add bits. I've got most of the bits and I'm going to fit it into an old gauge I've got lying around in the garage.

Sweet man, where in Norfolk are u

Nice looking!

nice!

Thanks for the comments.
I took the sump off last weekend as I thought after 168,000 miles it might be a bit cruddy but it was pretty clean! I got a lambda probe and all the bits I need now so I can start to make the air/fuel meter. That will give me something to do whilst I'm off work for the next few days.

Wiggy, I'm in Watton just south of Dereham.

Ever heard the saying 'Ignorance is bliss'?
Fitted my lambda probe so I could monitor the air/fuel mix of the car as standard before I do some engine mods. After a few earthing problems I got it working but the results threw up more questions than answers. According to the gauge I'm running really lean
Not sure if I believe it yet, I think I'll just get on with changing over to the weber and see how it goes!
I'm going to have a hot bath and a beer first though, I'm getting too old to lie on the drive.

T wrote:I'm getting too old to lie on the drive.

Know the feeling mate

Looking good so far, keep the updates coming

Well, started the week with a plan:
Remove carb and inlet manifold
Replace exhaust manifold and downpipe with GTi ones
Refit inlet manifold and fit Weber
Replace cam belt and cam with GTi cam
Drive away happy!

Didn't quite go like that though!!!
First stripped the air filter off and started to take off the pierburg and all it's associated parts, how many wires and tubes does one carb need?
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Got the pieburger off quite easily but got a bit stuck with the inlet manifold
After a bit of thinking, swearing and rooting through my tool boxes for an extra long 6mm allen key I gave up before I started. I could do with a new set of fingers that don't resemble sausages as well.

Decided to do the cam and belt first. I already knew that the crank pulley was a bit rusty, well ok a lot rusty. After lying on the ground in the rain trying to take of the allen bolts holding the pulley on I remembered I had this!!
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After kicking myself quite a lot the pulley came off no problem. I definatley need a new one, it looks like it's been welded before but time has taken its toll on it.
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Fitted the GTi cam without any dramas but the belt nearly led to a paranoid meltdown. I've been led to belive that the valves can't hit the pistons on this engine but I still chaecked every timing mark about a million times! Turned the engine over by hand a few times to check nothing crashed, banged or wolloped then had a brew and a rest.
Got the weber fitted as well, pics to follow. Refilled the coolant and turned the engine over half expecting things to disintegrate but it started up fine with a healthy 1600cc roar!!

Test drive in the morning!!!!

Test drive went well! Got back when I had warmed it up and checked the timing which was out. Reset that and set up the idle and went for another drive. It's running a bit rich but seems pretty good so far!
Some pics of the weber:
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one with the pierburg next to it, the weber is a lot simpler and smaller.
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VW have kindly provided a hole for the choke:
before[You must be registered and logged in to see this image.]after[You must be registered and logged in to see this image.]
Whilst fitting the carb I found out why it was running lean with the pierburg, the rubber manifold gasket thing had split! I replaced it with a new one when I fitted the weber. Hard to tell whether it's the car and cam or just that the timing is set correctly and there is no leak but the car is a lot better to drive. I suppose the only way to get it set up is on a rolling road but that will have to wait for some more money (as always). I live round the corner from Emerald tuning and I think they charge £40 for a run but that is without any tuning just a run on the rollers, I'd better get saving the pennies or maybe tax the kids pocket money?

the weber realy makes a difference! I had one on my Golf Drive 1600 for years. If you ever want more air, DONT get a pancake filter as they just suck in the hot air. I chopped of the main part of the standard airbox front section and used a k&n panel filter

If you ever want more air, DONT get a pancake filter

My weber actually came with a pancake filter. It's not ideal and I'll probably refit the stock airbox or maybe make up a new one. I need to make a catch tank for the breather really as I've just got one of those mini filters on it at the moment.
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Found an old car mechanics mag fitting guide for the weber after I'd fitted it as well!! Would have been useful before I started really!
I've not really done many mods lately. I put my foot down to get past someone the other day and snapped the fanbelt but I don't think that counts as a mod I managed to get it changed before they caught up with me though! ( I keep the old fanbelt in the boot when I change them on a service)
I've got a gti head on the way. I'm going to have a practice at porting it a bit. If I do a good enough job I'll fit that along with the Gti exhaust manifold I have which should pep it up a bit more.

Head arrived and looks in good nick:
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came with the inlet/exhaust manifolds, throttle body, injectors etc.. not bad for £20 delivered form ebay![You must be registered and logged in to see this image.]

Just had a good run out to portsmouth for work (about 190 miles each way) and she ran well. Returned 40mpg which is a result, I wasn't sure how the weber and GTi cam would affect mpg but it hasn't altered at all.
Lambda sensor packed up on the way back though so I'll have to have a look at that this week. It may have been a coincidence but it went just after I filled up with Shell at a motorway service station. It started showing a weak mix but engine seems ok so hopefully just a sensor problem, luckily I just use it to monitor the mix not control it.

Head looks i good nick like ya say bud hope it is just a sensor problem because the MPG sounds great

Started stripping the head down today, exhaust studs and water pipes came off ok. Took a while to suss out the valve spring compressor but I got the valves out eventually!! I started cleaning one of the chambers up a bit but a lot more to do.
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Ports need a good clean as well:
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This I want them to look like, a lot of work to do :
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My golf tuning manual shows that the injector air bleed needs blocking off but there isn't actually a hole on this head. One less job to do!
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I will need to block the injector holes off though. Not sure how yet, I want to use something other than pennies under the injector seats, maybe a short threaded blank instead of the seat.
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Really enjoying this and can't wait to use the dremel in anger . It's taking me back to my vespa porting days!
I'll see how I go, the head was cheap so if I mess up at least I had some practice.