all that is left to do is make a little pipe to weld in for the fuel pressure regulator vacuum reference, and tap some threads for the throttle body and accelerator cable bracket

Looking good Tom,

To the untrained eye, looks a nice selection of bits of an engine

So have you got this going yet then tom?

nah, been doing 12 hour days at work doing some poxy musical..

not far off though

nah, been doing 12 hour days at work doing some poxy musical..

not far off though

Then along comes panto season and you're doomed

Still glad to see it's making good progress

Just read all 17 pages and I'm staggered at both knowledge and determination...there should be an X Factor for car genious...flabbergasted!!!

all finished now:D, all the threads are tapped and made and welded in the relevant pipes then had it powder coated gloss white.... at least it fits under the bonnet now:)

Before:

After:

Progress!

Keep it upTom.

Nice work Tom

this feels like i've gone forward 1 step then gone back 3....

been having fun trying to find a suitable gasket for the mk3 head, there are subtle differences in the combinations of gasket and cylinder head, it's easy putting a mk4 head on an early block but not the other way round...

it appears that i need to fill up these 3 holes because of a difference in the gasket so i've made up some plugs to go in

Its all progress if it means your getting nearer to turning the key for the first time! Get a move on! I cant wait to see this finished.

Edited 4 November, 200817 yr by oldeboi
Fat fingers!

here's the aforementioned holes filled in

they are 'interference fit'

right, just to explain a bit, here's why i have to fill in those holes.

mk4 golf gti 2.0 cossflow 8v head

mk3 golf gti 2.0 sidedraught head

notice that the second oil drailback slot is elongated on the mk4 head, and is circular on the mk3 head.

so if i use the mk4 gasket i end up with a gap like this

so i need to use the mk3 gasket instead which is for the circular drain slot

mk3 golf gasket on, now you can see why the holes needed to be filled in

next, the manifolds need to go on before the head is put on the block

she's on

i've done a quick trial fitting of the throttle body

it fits the manifold ok, but the two pipes on the top foul on the bonnet, this will be solved by simply pulling the pipes out, they are not needed as this is a water heated throttle body and i'm going to use it without, plus also the engine is going to drop approx 25mm at that end anyhow

Is the water heating to stop frosting up a la carbs or for some other reason?

i can't see that freezing would be a problem on fuel injected cars, i suppose it reduces emissions or something

The throttle body's a Golf 3 one isn't it? If so, the water heating system was part of an economy system Vws and Audis used from about 1980 to the mid 90s.

Incidentally, if there's a venturi and flap valve throttle, there is a possibility of venturi icing, because that is caused by the pressure and temperature change effects through the venturi.

yeah it is a mk3 obdII throttle body, there is a small ventruri but only on one side, it is a very odd design imo

Looks like most of the hard graft has been done Tom,

When do you reckon you'l be turning the key?

:woohoo: the new hydraulic lifters are here

i still need to make a spacer to go behind the timing belt tensioner and a few other bits and bobs though