I have owned had this car for at least 4 years, just sitting in storage while I slowly hoarded parts. During that time I built and sold multiple other cars. A few VW rabbits, a S1 Scirocco, a Mercedes 190e cosworth, a VR6 passat, and an aborted Galant GSX.
once I sold the Galant I had enough to buy the last few bits I wanted for this car, so from then on its been all go. I brought all my hoarded parts and a bunch of extras to my brother's place and began the teardown.
Here he is ready to assist
What I started with:
From what I can tell, based on the tags that expired in 99 and the newspaper in the back dated sept 7, 1997 (coincidentally my brother's birthday) this car was sitting for a LONG time before I got it, probably because of the shredded timing belt and subsequent hole in the piston. Anyway, pulled the 1.6, set it next to the incoming 91 2.0, and pushed the car outside to clean the engine bay.
From this:
To this:
and This:
To this:
I am also eliminating some unnecessary stuff on the firewall and relocating some other stuff. In some circles this is referred to as a "mild tuck". I am keeping Power steering, relocating the alternator for both durability and appearance, trimming the timing-side motor mount and using the 1.6 (also N/T) OFH. I will keep an eye out for a 90 turbo OFH for a future project, I just didn't want to run the 91 style
The power steering pump mount has been modified a wee bit to be less chunky.
(the topmost nipple in that pic was also trimmed off once I realized that I din't need it either)
I also rebent the fuel feed/return lines as well as the hydraulic clutch line to lower points on the firewall. The clutch line will come off the firewall with the shifter cables.
The engine was assembled initially with one of those eBay BSE kits by a friend for his automotive class. He may have gotten a good grade on it but I was less than satisfied with the results. He not only put the longer oil pan bolt in the ONE spot that is supposed to have a short one, he also managed to strip that hole so I couldn't just swap them out. OK, since I have the 1.6 right next to it I decided to swap the front cases. $10 for a Front main gasket set and a few hours later, I had the 2.0 apart. while I was in there I thought it wise to swap the OEM stub shaft in as well as the new gasket. Good thing I did because HE LEFT THE BOLT LOOSE ON THE GEAR. I can imagine the chaos that could result from a siezed oil pump so I resolved to double-check everything he touched from there on out. So far so good. I have the motor retimed and on its way to completion.
For reference, Ebay stub saft on the left, OEM on the right:
While it was out I also purple-powered, wire-brushed, and pressure washed the tranny.
Before:
After:
I also determined that the 15's I planned on running for the past few years don't fit over the GVR4 brakes, only the stock turbo brakes, so I picked up some GVR4 wheels from TheDSMguy about an hour north of me and now I don't know what to do with these old (1990) 15x7 Artec wheels.
I think it will come together nicely.
~joe
