A 2.0 felicia, will scare a few drivers.

Nice work Tom.

big chunky piece of aluminium turned up in the post today... crikey that was quick

made a little progress today...

this is the bracket all clamped up ready for welding.

Edited 18 August, 200817 yr by TeflonTom

all being well the finished mounting should be ready by tomorrow

Looking forward to this being dropped in

yeah me too ross, although i'm still minus a few bits and bobs, i need a suitable throttle body for a start, the drive by wire one that i've got is a no go, so i'm going to go to 'ole scrappie' to blag some mk3 gti injectors and hopefully iirc the mk3 gti throttle body has the same bolt pattern as the later crossflow engine???

If you can get me a part number I may be able to find one, we have a fair few older throttle bodies kicking about in the back of the workshop, one of our licence techs likes hiding them kinda things but i've found them

etka says 037133064 for the mk3 gti throttle body, i've just had a further thought, the mk3 has an external idle speed control valve so it may not be suitable... :rubchin:

there was a slight last miniute design change to allow clearance for the timing belt tensioner

Edited 18 August, 200817 yr by TeflonTom

next i dropped a blob of weld into each of the aux air injection ports to seal them off... notice i have removed the studs to avoid the risk of the arc flashing across to the steel studs during welding

i then took it to a machine shop where i used to work and they very kindly let me use a baby surface grinding machine for a few moments to grind the welds flat.

Before

After

if you look carefully you can still see the welded patches

set up on surface grinder for skimming, it didn't actually need skimming at all but i thought i might as well do it while i had access to the machine:)

Before

After

mounting bracket fitted to the engine block, it is necessary to modify the lower timing belt cover slightly to allow this to fit in, i spent a few miniutes with a junior hacksaw cutting.

hopefully i should be able to re-fit the cylinder head and start putting some of these bits together in the morning, i'm still waiting for the clutch to arrive though

flywheel from felicia diesel (AEF)

EBC clutch kit for felicia 1.9 diesel purchased from ebay for £30

not all that interesting folks, but i've started assembling the engine

just a few more loose ends to tie up....

Its interesting to me

I am watching this with interest as well.

had 5 mins to spare earlier at work so i quickly rustled up a flywheel locking tool to assist in doing up the bolts

also i need to figure out a way of closing off this gap otherwise the engine bay is going to get caked in clutch dust :rubchin: i think maybe some 2mm ally sheet:)

exhaust manifold from vag 1.7/1.9 sdi diesel engine... approx £20 from breakers yard:)

still haven't got to the 'good' bit yet folks:) bellhouse adaptor and flywheel fitted, but i can't find my clutch centralizing tool at the moment:O

home-made tool in place

ooh i forgot to mention this....

the stud in the gearbox (arrowed) has to be removed for it to fit

why so??