205 Gti6 To Gti6 Conversion Help

[dcc 855]

subframe is just 6 bolts and 1 on the steering column, much easier to just get it off, the batt tray has 4 bolts, 2 are hidden along the side, in the engine bay. bumper is just a little tricky to get off but essentially just 4 bolts afaik, drop engine to the floor and remove gearbox. saves SO much hassle in the long run if your takign engine out by your self!

[Anthony 1,003]

I'd leave the front bumper in place unless you need to remove it - it's one of those jobs that should be dead easy, but inevitably half the nuts/bolts will be rusted solid and will snap

 

I'd personally say that there is no need to remove the subframe providing that you've got an engine crane as it's simple enough to lift the engine in and out from above. Removing the subframe just creates more work and opens up another potential can of worms, and why risk more issues than you need to when you're working with 20+ year old bolts and captive nuts?

[pugpete1108 62 1 Cars]

unfortunatly i think the bumper will have to come off anyways.

 

i was down sorting out the welding on sunday and found plenty of surface rust and paint bubbling behind the headlights on both sides.

 

whilst the engine is out, it makes sense to treat all the bad bits and then put it all back together

 

i know what you mean though,nearly every bolt on this graphite front bumper snapped while i was trying to remove it. i even had to cut a foglight bracket as both bolts were fubared

[damien 22 1 Cars]

as pete said, the front bumper is coming off anyway now to treat the rust problem mine has got.

 

i think removing the subframe would of been more work than what was needed IMO.

[damien 22 1 Cars]

bit of a update if anyones intrested (mite be worth turning this into a project thread)

 

before -

 

 

 

 

 

 

 

Edited November 27, 2011 by damien

[damien 22 1 Cars]

the engine bay all cleaned up and painted using some VHT black paint.

 

after -

 

 

 

 

[pugpete1108 62 1 Cars]

looking good mate.

 

is that how the matrix hoses go then? i put the top one to the header tank and the bottom on the the engine? may be why im having trouble bleeding it then

[damien 22 1 Cars]

i didnt think it mattered..... ive got loads of pics of other peoples which is a mix/match

[damien 22 1 Cars]

the old engine stripped down

 

 

the new engine stripped down

 

 

306 PAS bottle

 

[Masekwm 2]

Please can I have your old engines engine mount bolts?!

[damien 22 1 Cars]

im reusing them

[Masekwm 2]

Bollocks really? The ones that hold on the lower engine mount to the block?

Edited November 27, 2011 by Masekwm

[welshpug 1,657]

they're just standard M8 and M10 setcrews.

 

 

6913 J4 SOCKET SCREW DIAM 10X150-70

 

6913 G5 SCREW DIAM 10X150-45

 

(6913 V3) superseeded by; 6913 96, SCREW DIAM 8X125-30

 

[Masekwm 2]

Yeah, it is the others 691778. I'm going to have to send the wife to a bolt place in the next week or so.

Edited November 27, 2011 by Masekwm

[damien 22 1 Cars]

replacment engine cleaned up/painted/built up

 

 

 

 

 

[damien 22 1 Cars]

in it goes.

was alot easyer with the battery tray off and the upper engine mount.

 

 

 

 

 

[damien 22 1 Cars]

got some trimming to do to clear the M/C

 

 

 

 

 

 

im back at work now so its all stop for afew weeks, im going to get a longer speedo cable, sort out a exhaust heat shield, trim the head/cam cover and sort the wiring loom.

Edited November 29, 2011 by damien

[damien 22 1 Cars]

head trimmed. im unsure if i should trim the cam cover, i dont really want to unless i have to.

 

 

 

 

now sitting on its own mounts

 

 

 

 

[chipstick 382 1 Cars]

Good work.

 

Trim the cam cover if it's forced against it. Don't go mad on it. I had my engine in and out several times so while it was in breifly I marked where to cut, and then when out again to sort the manifold out I cut it as much as required.

 

I wouldn't want to do it in the car unless you want to remove the master clylinder. But by the time you have lost the fluid etc, it would be quicker to pop the engine out again to do it.

 

Where did you get the load leveller from?

[pugpete1108 62 1 Cars]

how much did you have to trim off the other engine Daim?

 

odd how the tolerances differ even from engine to engine

[damien 22 1 Cars]

i got the load leveller for my birthday, i think it was from machine mart.

 

the old cam cover needed trimming loads, this one is only just touching. just abit worryed when the engine starts moving its going to do some damage.

[damien 22 1 Cars]

little bit of a update,

 

as the better half went off xmas shopping again!! i was left with the kids and some free time. i left the little ones indoors with the wii and i cracked on.

 

first thing was to set a old laptop up i got off ebay in the garage.

 

 

 

 

 

ive trimmed the cam cover back but not too much to expose the cam belt, even if it dont look like much i can fit a strip of paper inbetween the gap of the m/c and cam cover

 

 

 

note the thin bit of card that just fitsd in the gap

 

 

i was planning on fitting the driveshafts and the bolt the exhaust to the manifold but the floor looked abit on the cold side so i decided the test fit the rad/fan housing.

 

seems like the housing needs trimming down as the rad hits the inlet..... as with everyone else who has done the gti6 converstion

 

 

 

a quick test fit of the slam pannel,

 

again seems like some more trimming is needed to clear.... well everything

 

 

 

 

at least it dont look half bad

 

Edited December 24, 2011 by damien

[allye 530 3 Cars]

how much did you have to trim off the other engine Daim?

 

odd how the tolerances differ even from engine to engine

 

no, no, no! Engines are identical. Its the shells that are alarmingly different

[chipstick 382 1 Cars]

I would get a bit more clearance on the cambelt cover if I was you Damien.

 

A 0.5mm card isn't enough clearance IMO. The solid mounts are great at reducing movement, but will still move ever so slightly. They are rubber after all and the vibrations and hard cornering are likely to move it more than the thickness of a bit of card.

 

Is the servo spaced out? Make sure it is fully tightened if you have removed it or moved it more for any reason. I hadn't put a few nuts on the back of mine and it pulled it over - fortunately more so in my favour

[damien 22 1 Cars]

there is no spacers on the m/c.

i didnt want to chop too much off the cam cover, i dont want the cam belt exposed and covering it in tape (like my last engine) wasnt going to be a option.

your right tho that 0.whatever mm clearence just wont be enough, ive been toying with the idea of trimming the m/c but i just cant decide (or find a pic) of how much is save to remove.

 

i want to move on from the m/c problem now as ive been sitting on it for over a month now and this coverstion should only take a weekend (if i pull my finger out), ive been fart assing around with it for far too long now. its not like im doing anything special or out of the norm.