My Mk2 VR6

[chippy 34]

Been a bit of a lurker on this forum and thought it was time to start my first build thread!

 

Had my mk2 for a couple years and have always wanted a VR in it.

 

Here it was before it was off road two summer ago in all its glory

 

 

 

Fast forward to this summer, i began the strip down. Having spent the last 2 years collecting parts for the conversion, the donor car and well, parts i didn't need but i wanted lol.  

 

With donor car (parts are up for grabs still check cars for sale)

 

 

While i was stripping apart the mk2, i purchased a VR engine along with a de-immob loom, perfect for plug in play in a mk2 and a 6 branch. And i had the donor car for everything else.  Engine i purchased alone was sat round for a while so i decided to rebuild it with some extra goodies too

 

Took the engine to my uncles garage, and began the tear down.

 

The "goodies" i purchased from https://vr6parts.com/ schimmel performance in other words.  They have some top quality stuff. ill post the build below but, just give you the spec:

 

- 2.8 OBD2 

- 6 branch to 3" exhaust

- MK4 triple layer headgasket

- New guides, chains and tensioners

- 263 SP cams

- New genuine hydraulic lifters

- SP valve guides

- SP heavy duty valve springs

- SP valve seals

- SP titanium retainers

- SP high flow water pump

- Metal crack pipe

- All gaskets and seals replaced

- New starter motor and alternator

- light weight under pullies

 

- 2.3 V5 gearbox with diesel 5th and lightened flywheel

 

Gave the block and good clean and degrease.

 

 

Checked it over, no scoring off the bores and pistons just head carbon build up which i cleaned up.  It did shows signs of the 144k odd it done!

 

Head got the same treatment...

 

 

Whipped the cams out, lifters had seen better days so they where replaced.

 

 

 

Most the engine build took place over summer ...ill update with pics etc tomorrow

 

thanks for reading

 

 

[daveyboy 897]

Looking good mate. Gotta love mk2's. Can't wait to read the rest

[chippy 34]

Continuing from my last post...

Heres a pic during the head clean up

Then it was off to get the head skimmed!

Valves where all in good nick...just needed a good clean up!

Before:

And after:

Then i started to seat the vavles. First time i had a go at this myself, took a while but got the hang of it! Im glad its a 12v and not a 24v lol

[chippy 34]

The new valve springs, seals and retainers where installed. Old springs where ok but, since i was putting new cams and lifters i thought id upgrade springs.

Having got this far, i was glad i replaced most these parts! A lot was needed but others for peace of mind

Springs getting installed;

All assembled

Note: in my first post i forgot to add these bits before hand lol

But anyway, just to give you insight how bad things where:

Thats the old water pump v the new SP high flow one

Back to the build....

The 263s where installed. Cant wait to see how they make the VR feel.

Thats all for tonight! Im much further ahead in the build. But ill update tomorrow and slowly bring you up to date.

[chippy 34]

Update time.



So the head is pretty much done. The head was bolted to the block using new head bolts, along with the MK4 triple layer headgasket in hindsight i wish i went for ARP headbolts. But, ill upgrade to that when i eventually turbo it.




Next up it was fitting new timing chains, guides and tensioner.



Also gave the chain cover a lick of paint

Edited November 15, 2015 by chippy

[chippy 34]

Gave the sump a clean up and attached it the engine with a new gasket also the rocker cover with new gasket




New inlet runner gasket





Fitted the inlet runner and fuel rail installed after a lick of paint. Note the lightweight water pump pulley, had issues with this which ill touch upon shortly...

But first, i received my lightened flywheel! Be interested to see how this feels. Bolted up using ARP bolts





Replaced the plastic crack pipe with a metal one and new seals, it looks so much better and considering it was an ebay buy it was a great fit. Fitted the SP high flow water pump as well as a new thermostat and housing.  Brand new clutch and friction plate too.

Edited November 15, 2015 by chippy

[chippy 34]

Got the inlet manifold shot blasted. I was going to get it powder coated but, i ended up polishing the runners and rattle canned the rest. What PITA it was to polish!

Shot blasted


During polishing


Polish complete


The pictures actually do this justice lol. By far not a perfect finish, but im happy with it and it looks awesome!

Finished look:


Gearbox was attached along with a reconditioned alternator and starter motor. Starter motor bolt had to be cut for the DZL box to fit



Inlet bolted on. Was a joy to see how far its come! Some before and after pics of the block











Cheeky video turning the engine over lol

https://vimeo.com/145809043

So thats the engine pretty much done! Next update will be covering the running gear, engine installation in the car and a lil video preview of it firing up!

Thanks for reading

Edited November 15, 2015 by chippy

[ky_uk 304]

That's looking fantastic! I have just started mine it still looks like your before pictures

[chippy 34]

That's looking fantastic! I have just started mine it still looks like your before pictures

Cheers mate! Yeah mine was defo needed, headgasket was gone and a bit snapped off the guide rail and ended up in the sump! Glad nothing else was damaged.

I have been keeping an eye on your build, looking foward to seeing ur engine build.

[chippy 34]

Back again!

Right, i mentioned yesterday i had issues with the ebay under pullies, the one in particular was the water pump pulley. I messaged another forum user on here (cant remember who now) but he had same problems too





The alternator pulley bolted up with no issues.

However look at the size difference between the OE pulley and the "ebay special"



Due to the width and diameter of the water pump pulley, it wasnt lining up with the tensioner thus not allowing the serpentine belt to fit properly. After realising this, i also decided not to fit the ebay special crank pulley either. Ditched the water pump pulley too, and went for the OE one.

I was going to risk the time money and effort i sunk into this engine on a damn ebay pulley lol.

So word of warning to those considering these cheap under pulley kits, dont. I believe awesomegti do an underpulley kit, i cant comment on the fit and quality.

Id like to hear if anyones had any experience with them, particularly the crank pulley.

Exhaust manifold wrapped. Its hard enough trying get a neat tight wrap, without this stuff itching and irratating your skin! Horrible job to do



That concludes the engine build. So moving on

Go my subframe shot blasted and powder coated



Wishbones sprayed up too





After doing some research, i decided to run powerflex poly bush on the front and opted for the R32/TT bush on the rear. Seems to be quite popular set up for comfort and handling.

Ideally i would of loved some KW V1 coilovers, but the the build was getting out of hand and funds where running low. Good friend of mine runs FK AKs on his mk2 vr, and he recommended them. Hopefully better than the crappy JOMs i had before!



Didnt take many photos after the engine was done!

But, i refurbed and painted both steering knuckles, fitted brand new bearings and hubs. I was after some splash shields, but i refuse to pay £30-£40 for a piece pressed metal sheeting which is only going rot!

So i salvaged the old one, lick of paint and supported the bolt holes with some washers.



Also refurbished the driveshafts, fitted new joints and gaitors which, i have no pics of

Brakes got an overhaul, blasted and sprayed silver for an OE look. Not to keen on blingy brakes unless they're brembo's, wilwoods etc





Lil preview of my hoard of been collecting over the years, NOS happich pop outs



And a rallye front! which i could wait to put on when i got it haha



More tomorrow!

Edited November 16, 2015 by chippy

[bennyk 1,238]

Really nice car and a good read! Love Rallye front ends on mk2's! And you've saved me from buying a set of those eBay pullies that I've been thinking about for a while, so thanks for that

[chippy 34]

Really nice car and a good read! Love Rallye front ends on mk2's! And you've saved me from buying a set of those eBay pullies that I've been thinking about for a while, so thanks for that

 

thanks mate, the car doesn't reflect the quality of the engine build unfortunately!  good good, i tend to do a lil research before buying these ebay parts, couldn't find much on them so took the gamble on them and reported back to everyone else! awesomegti sell a set, more pricey so i guess it'll justify the quality??

[chippy 34]

Carrying on!

With the engine done and front subframe assembled

I turned my attention to the rear beam. Got it shot blasted and powder coated. I cleaned up, sprayed and applied grease to the stub axels

Manage to salavge the old splash shields, gave them a coat of paint!

Installed new hubs and powerflex bushes

With the assembly of the car happening at a family friends garage. It made sense to get the car recovered there. In the mean time, i started on the loom! I delayed this as much as i could as i hate wiring! But it had to be done lol

The loom was removed from a mk2 vr luckily.

With the golf now at the garage, i could finally start bolting all these new shiny bits! I also modded the shifter tunnel to allow for the mk4 shifter tower, a worthwhile mod people say. A more precise gear change (no pics unfortunatley!)

And my fav pic, engine in

As me and my uncle where desperate to here the engine, we wired it up, put fresh fuel in...and ohhh the noise, how i missed the VR noise

Cant upload the video at the mo

But that pretty much brings u guys up to date. Once the engine was in i wish i tool more pics during the installation but, theres still plenty work to do

Updates will be slow and steady

But here how she stands at the moment, not looking here glorious self 2 summers ago lol

Thanks for reading!

[chippy 34]

Managed to get the video uploaded

https://vimeo.com/146499079

[ky_uk 304]

Music to my ears!

[c00k 435]

Looks and sounds good buddy!

It was me you messages about he eBay pulleys.

I did the same fitted water pump pulley, and removed it all most straight away.

Keep up good work man

Edited December 10, 2015 by c00k

[chippy 34]

Looks and sounds good buddy!

It was me you messages about he eBay pulleys.

I did the same fitted water pump pulley, and removed it alarmist straight away.

Keep up good work man

 

Ahh yes.  i was reading through your thread and you just happened to be using them too lol.  but yes the fit was completely off, yet the guy still seems to sell so many :S

 

thanks bud!

[chippy 34]

Not really an update per se.  But just things planned down the line! My gf got me these wheels pretty much when i got the car lol.

 

they're compomotive cxn splits in porsche fittment 

 

specs:

 

16 x 8 et 25 fronts

16 x 9 et 13 rears

 

Theyre gonna need some messing round with to make them fit lol.  i want them to sit flush with the G60 arches that i purchased before i even got the mk2 haha.

 

hopefully more updates next week! on thursday at the garage hope to connect all coolant pipes, and let the engine run for a while!

 

 

 

[chippy 34]

Fitted a mk4 expansion tank, really does make a difference loosk wise! Not realising the coolant plug was different to the mk3 one i managed to cut one off a mk4 at the scrappy, just need to solder it onto the mk3 wiring. Happy days

Got the radiator in too and slam panel on just to check any clearance issues. Everything sat nicely so issues there!

Next update will probably be after the new year now. Where ill have more money and more time! Have a good ones guys

Edited December 9, 2015 by chippy

[chippy 34]

Been a while since ive updated this. But work on the golf came to a halt due to funds and other commitments.

With summer coming up and money to chuck at the money pit, i aim to get it on road end of June.

Yesterday i dropped it off to a mates so he can do all the wiring as i hate wiring

More updates on the weekend hopefully

[matty.vrt 120]

Hope to see you finish it. Great work so far, the engine and gearbox look better than new.

[chippy 34]

So my friend made a start on the wiring this weekend gone.

Had a lil problem decided which fan set up to use, as i have golf vr6 wiring put corrado fans.

In the end decided to go for twin spal fans an 11" and a 9" wired to a switch. They'll look better, neater and probs cool more efficently

[chippy 34]

UPDATE

So i have been getting back stuck into this build again.

Managed to get hold of pair of power steering pipes, which took me almost a month to get hold of! Not exactly rare parts either. But thanks to another forum member on here, i got one

Gave em a clean, sand and degrease. Then i coated them in underseal, not a show stopping finish but its presentable, durable and hopefully wont rust!

[chippy 34]

So after returning back from holiday. The day after i got stuck in.

Started by tidying up the loom, wrapping the engine loom in conduit and the interior loom in tesa tape.





Also completed the mk3 golf stalk swap








I modified the dash to make the mk3 clocks fit, dont have any pics of this. But it was long and frustating task!



Focuses my attention back to the engine bay, the servo and master cylinder where lookig rough. Didnt compliment the fresh looking engine.

I removed em, gave them a lick of paint





More updates soon.

[c00k 435]

Looking good dude, 

keep it up man