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Update 64:

So I really want to go to town with this engine conversion and I want to be thorough with it. First things first then, whip off the DSG gearbox. It's no good to me as I'm going to be running a VR6 one. The DSG one is massive and weighs a tonne! 

Photo-09-10-2018-17-54-34.jpg

I need to next remove all the engine loom and then onto the ancillaries and inlet manifold. The block is going to get painted to look factory fresh, and all the bolts, ancillaries, brackets etc are going to be refurbished or replaced where required. To make my life easier, I thought I'd buy an engine stand.. much better than working on an old tyre. 

Photo-11-10-2018-15-49-44.jpg

Here she is.. my colossal engine stand lol! Gearbox and transfer case off, the engine was a bit of a mission to fit onto the stand, but I got there in the end. I wanted to mount it from the rear side of the engine so that it leaves the gearbox side free for bolting up the VR6 gearbox and to do the timing chains. It's so much easier to move the engine around this way, and its a much more comfortable height to work on it too. 

More pics:

Photo-11-10-2018-15-49-36.jpg

Photo-10-10-2018-17-19-44.jpg

Next steps are going to be remove everything I can to get the engine block to a stage where the timing chains can be done, and I can then start the process of sanding and painting it, before reassembly begins. 

 

Gurpal

 

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Dude good to see you again on here! I've just updated mine too, how funny we're at the exact same stage of just starting an engine conversion!

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On 10/28/2018 at 4:04 PM, brilledwards said:

Dude good to see you again on here! I've just updated mine too, how funny we're at the exact same stage of just starting an engine conversion!

Hey man, hope you've been well! I will definitely be giving yours a read over! 

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Update 65:

Continuing to strip down the engine so I can clean and paint the block as well as do the timing chains too. Main things to be removed today were the ancillaries and inlet manifold.

Photo-15-10-2018-13-36-26.jpg

 

To be fair it was all quite straight forward, it was only nuts and bolts mainly. I encountered the odd few rounded nuts and bolts but that was always to be expected. Working on the stand makes life so much easier. 

So here's the state of the engine after I'd finished with it for the day.. 

 

Photo-15-10-2018-17-05-31.jpg

 

Photo-15-10-2018-17-05-37.jpg

 

Photo-15-10-2018-17-05-50.jpg

 

I've placed my order with TPS for the timing chain parts. Until then, the next thing will be to remove the VR6 from ANN and then after that it'll be onto cleaning the gearbox and ancillaries. 

 

Gurpal

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Update 66:

Next job now that the 3.2 was stripped down was to remove the 2.9 engine and box from the car. This would give me the access needed to get the loom out which is going to be sent away to be spliced together with the 3.2 loom so I can use the CE2 fusebox. 

 

Taking the engine out was fairly straight forward. I done things in the following order:

- Drain all the cars fluids. Oil, coolant and power steering fluid were all drained. These are simple enough to do. Took all of half n hour really due to the power steering pipes being a bit difficult.

- Remove as much of the extra items surrounding the engine as possible, for instance, the air intake system, expansion tank, fuel lines, battery etc

- Doing the above step gives you good access to unplug the wiring harness. This was the next step.

-  I then proceeded to disconnect the clutch slave cylinder, unbolt the cat from under the car, and also unbolt the shifter linkage. 

- Next thing was to get the crane in place and strap the engine up

- I then unbolted the engine mounts and used the crane to free the engine. I wiggled it out slowly and a second pair of hands helped guide it up over the bumper and out.

Front end stripped down and the fluids being drained:

Photo-16-10-2018-11-01-53.jpg

Engineless bay:

Photo-17-10-2018-14-19-32.jpg

Engine  out:

Photo-17-10-2018-14-19-41.jpg

So next thing now is to remove everything else in the way in the engine bay, which includes the wiring harness. 

 

Big thank you to Hardip for the extra set of hands and thanks to Sukh for lending me the crane!! 

Thanks for reading 

Gurpal

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Update 67:

Continuing on from the last update I began removing the parts from the engine bay that were inaccessible with the engine still in. This included:

- Brake servo and master cylinder

- ABS pump

- Wiring and clips

Mid way through:

63-FA084-F-D302-427-E-AEDD-8-D831-FDF8-D

Then the rest of the loom was pulled out along with any other parts. This pic was taken after I pressure washed the engine bay too:

1-EF71-EFA-5-C37-4-A13-B158-0-EE0-CD3-FE

So my olan is to give the engine bay a fresh coat of paint so it’s clean and tidy for the new lump to go in. I’m not going to go crazy and smooth everything. I want it all to be neat and tidy, but functional and clean. 

Thanks,

 Gurpal 

 

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Update 68:

I begun stripping the interior of the car too. There are a few jobs that I wanted to do here with regards to the dash, wiring and body of the car. These include: 

- Sorting the radio and speaker loom out. I'm gonna make an entirely new radio harness from scratch and also all new speaker wires to amp's mounted behind the rear door cards. Taking inspiration from the build done on the bright blue metallic Mk2 by Studio In Car. 

- Sound deadening all panels and areas of the car including the bulkhead, firewall, boot floor, turrets, C pillars and under the rear bench. I'm gonna use some silent coat for the deadening and then some isolating material on top. Want the car to sound and feel properly put together. 

- Before removing the VR6 engine, the car was suffering from a battery drain somewhere. I'm guessing it was to do the with the heater blower motor loom because I could turn it on without the key in the ignition. Same with the radio too. 

- There are no interior lights other than the dash lights either. I want to wire these in properly too. 

- I'm also going to sort the boot build out for the air suspension. Do a neat and tidy install that still gives me some boot space to put my subwoofer in. 

- The heaters work but the flaps inside could probably do with some attention. The bowden cables are also very stiff too, so I'm gonna address these issues too.

 

Initial removal of lower dash shelves, radio, heater controls, clocks, steering wheel and dash fascia:

FAD2-A1-C1-9730-41-BC-BA17-6631-C99-FEC9

 

FFA0-DD41-B827-4-B4-B-9022-A3-A6-C67-EA4

 

Dash out, heater box on the hit list next along with fusebox and associated wiring:

6357-C482-F0-B0-4-B0-D-A5-F7-F1-B9-F8-C7

 

Next step is to remove all the rest of the wires, pedal box, steering column and any of the old sound deadening. 

Until next time! Thanks for reading

Gurpal

 

 

 

 

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Update 69:

Managed to remove the pedal box and steering column from the car. Fairly straight forward, all nuts and bolts really. Also removed the clutch master too. I also stripped some of the old sound deadening from the bulkhead. I'm planning on redoing this with fresh stuff after giving it a good clean underneath:

4-A9822-DA-9602-424-B-9-D97-272-B58923-D

 

Wiring down to it's bare bones here now. Just the electric window wiring loom and the rear lights and fuel pump harness left in the car now. Gonna strip these down, clean and rewrap in fresh loom tape. 

47295-D6-C-4952-4439-B259-F629-BDE296-F5

 

More updates on the way! 

Gurpal

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Update 70: 

So whilst I've been working on the shell, I gave the engine over to a local mechanic to get the timing chain done. I've never done a timing chain before, so I didn't want to experiment with this one. Although there are fairly detailed DIY threads and videos on the net, I still didn't fancy taking the risk. Maybe on the VR I've removed I'll attempt it when I look to rebuild it. 

So here is the engine on the stand at the mechanics workshop with the timing chain covers off. I'm gonna get these acid dipped and blasted, then give them a coat of silver paint: 

3-F88-AD6-F-48-C1-42-B5-BAC5-EB5439-AEA0

 

Here is the new timing chains installed before the covers go back on: 

C0405-E38-7-CF9-470-A-885-D-F2-B9-D11340

 

Will get some more pictures when it's back and the newly painted covers are fitted. Then will start work on cleaning and painting the engine block. 

Gurpal

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