Meet K.A.T. MK2 Golf VR6T

Ok, havent worked on KAT for ages so as it didnt rain today thought i'd better get off my arse and get her running! First up fitted the new Genuine oil pump, pump driveshaft, and also oil pipe from pump to block. Then fitted new sump gasket and refitted sump. Also fitted oil filter housing and new Oil filter. Next was to fit a new dipstick tube and rubber ring as the old one was damaged, filled engine with cheap oil for now as i will need to do change after a few weeks of running. Carried on with a few other things then noticed a shit load of oil on the floor, so looked underneath and had forgotten to put sump bung in!!!!! doh Sad So fitted that, nipped to shops and bought another 5 litres of oil and refilled.

Connected all battery leads to Starter motor etc and fitted new battery. Did a Continuity test from battery to main feed to make sure i had no short circuits before connecting - all was good so connected battery terminals.
Went to turn the key and realised i had forgotten to connect plug to ignition barrel, then i remembered why i hadnt connected it, it was diffrent from a 90 spec plug. By this time it was starting to get dark and just wanted to hear it crank over so shorted it out on the starter motor, used my meter on the oil filter housing plug to make sure i had oil pressure which i did and she span over quite nicely. It wouldnt fire yet as i have no ignition leads for it, and also need to sort that ignition barrel plug which i'll do 2mrw.

I was wondering what was going on here Si, how long do you reckon it is going to be before you are done??? It seems you are getting right on top of it now.

hopefully 2mrw i will cut the ignition plugs off and re-solder them to the vr6 loom. Once plugged in, attach the fuel lines, and HT leads and she should fire up!

Then its a case of find a suitable radiator and fan, finish a few things and get her in for MOT and Tax.

Cool, end of month meet then???

better be si. you are taking ages! ended up staying at the butchers till 6 this morning! u shuda come

Mr Scoops wrote:

Cool, end of month meet then???

haha we'll see.still cant get hold of a corrado vr6 radiator for it. rare as rocking horse sh!te!

Finally found myself a cheap Corrado VR6 Radiator, and bought some genuine VR6 HT Leads!! (not cheap! )

Also decided instead of cutting and splicing the Ignition barrel loom, i may aswell just go to a breakers and get a later spec barrel and Indicator / wiper stalks which will just plug straight in to VR6 loom. So thats what i did, except i got a set of Mk3 VR6 indicator stalks which are chunky and feel nicer to hold.

After connecting everything up i reconnected battery and turned on ignition to position 1, the speedometer lit up with clock and mileage, and also the Oil pressure warning light came on dim, when i moved ign switch to position 2 the lights went bright, and then when i went to start it nothing happend at all and all lights went out. Car didnt turn over, and fuel pump didnt prime!

Strange..... i have rechecked all wiring and cant see anything wrong, it cant be battery as it is a week old!

Think maybe i have left an earth off?!

Some up to date pics

The Calipers are pretty close to the 15" Steels



Some pics of the wiring in progress





Some of the underneath, Uprated VR6 Antiroll bar, and custom made downpipe to house Lamda probe



De-Cat section of exhaust



VR6 External fuel pump and filter



Pics of car with VR6 Radiator



Rear of car

SimonABT wrote:

Some pics of the wiring in progress

You are mental!!!!

mmmmmm wiring lucky you

your resto thread gives me a headache dude


are they alway's this complicated ?

Hey Si have you seen the Caddy that Spliteye is building on VZI??

http://www.volkszone.com/VZi/showthread.php?t=461979


This man is chuffing mental...

just looked out it rich that will be mental but cool

thecrewkid wrote:

Hey Si have you seen the Caddy that Spliteye is building on VZI??

http://www.volkszone.com/VZi/showthread.php?t=461979


This man is chuffing mental...

No way!!! That is exactly what i wanted to do with my next Caddy if i get one!!

Fair play to him, looks like it will be a beast!

Update on KAT......

Spent the last 2 days arsing around and had no joy getting her fired up, completely disconnected all wiring inside car, then cleaned all terminals and reconnected them back up, reconnected all earths in Engine bay, found some wires that had snapped off so re soldered them back together. Now i have working head lights, wipers, and the car will turn over on the key now!

Still wont fire tho!!! So yesterday me, dad and my cousin (maltloaf on here) spent the whole day trying to trace the problem, we found that the two fuel pumps are opposing each other (both are pumping towards eachother) and also still no spark at the coil, so after testing endless things we think the problem is in the Crank Position sensor... because the sensor is at the front of engine it is likely it wouldv been damaged in the accident, if this is damaged it wont send a signalk to the ECU to say 'Spark'. So next week i will get a new one and fit it and also fit a new External fuel pump.

Its just never ending!!

Pictures paint a thousand words.......




After 11 hours of fault finding dads face says it all..... haha

tidy mate to many wires though wouldnt no were to start and thats one of my hurdles up and coming

itsabuglife wrote:

tidy mate to many wires though wouldnt no were to start and thats one of my hurdles up and coming

What conversion you doing mate?

just a 1.6 gti on twin carbs for the mo and if i keep it long enough a 16v on twin webbers maybe

SHE RUNS!!!!!!!!!!!!!!!!!

Turns out i had the wrong relay in position 3 of fuse box so fuel pump wasnt running properly, also found out why it wouldnt fire, the crank position sensor was damaged and there was no 12v feed to the ECU. So fixed crank sensor, and found a red/yellow wire floating in back of fuse box which was a 12v feed, so plugged it in and hey presto!

The car has a bit of a misfire and no compression to start with but once she had been started a couple times she is fine. The misfire is down to knackered HT leads, and i have a new set to replace them with 2mrw.

Also still have a problem with the fuel pump, when the battery is connected it primes continously and wont turn off even if engine is not running?! Need to have a look at the wiring to it 2mrw aswell but dont think its too much of a big job.

I will try and get some vids 2mrw just so you can hear the sound of it! Truely evil!!

Well done Si!!

Still major problems with the fuel pump wiring, spent hours and hours trying to track down the problem and still no joy. Basically the pump is getting a 12v perm feed from somewhere, but even when all other plugs are unplugged, and when all fuses and relays are removed it still runs?! Ive tracked down the pin output from the ECU to fuel pump so if worst comes to worst i will just cut into this wire and have it on a switch. It should be ok, but just means everytime i want to start car i need to remember to turn pump on 1st, and vice versa when i turn it off. Should also be a good anti-theft device too.

Other than that, ive replaced the Mk2 Power steering pulley from a V-shaped one to a Mk3 VR6 Toothed type pulley, fitted a new Belt and tensioner, and made up some new brake and clutch lines. Just need to bleed the system sometime.

Getting there slowly but just havent got the enthusiasm to get motivated and get it done!

Ever since i fitted the Injectors and fuel rail i have had a funny feeling something was missing, and today i found 6 horse shoe clips that i had left over. So off came the Inlet manifold and my suspicions were right, i had forgotten to fit the Injector clips that hold them in place! Also noticed i had a leaky injector so i removed it and found the rubber O-ring was buggered. So i'll order an new set from VW.

Also i got distracted today and decided the standard fuel hoses looked boring, so i made up some new Stainless braided ones with high pressure fittings so i could fit a Pressure gauge. This will also make it easier to see what fuel pressure im running once i decide to fit the regulator when i turbocharge the engine.

keep up the good work fella

Does the phone make it go faster?

Last night had a massive break through with the wiring! Got it all sorted and now fuel pump only primes for a second when ignition is turned on. Also sorted the missfire by fitting new seals on injectors. Starts and sounds sweet!! Also made myself a 3" straight through exhaust system with 1 rear silencer.(sounds like a beast!!)!!

Finished connecting all brake and clutch pipes and tonight i will bleed the system and hopefully drive it into the garage.