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I’m up in Hull – a long way from you I think…
Took the inline fuel pump from the GTI today – as the fuel sender on the syncro is located further toward the rear of the car (as the tank is further back), I will have to extend the fuel lines from the inline pump to the sender top – the fuel lines are fairly stiff standard items with flexible ends to allow for connections etc – I’m going to use the GTI lines from the pump to the tank and just extend the flexible parts. It appears that I can do this without removing the tank as I had a go at that today and it did not want to happen…
Ordered the rallye fuel sender today – about £65 including a new strainer.
Bought 2m of fuel hose and some clips so total spend so far = £77 (car plus fuel hose etc – I’ll add the fuel sender when I get the correct price). One of the reasons to catalogue the conversion is to track the costs and to explore any ways to save money etc…
One interesting point to note is that the fuel return hose on the syncro is a smaller diameter than the fuel supply hose (5mm vs 7mm I believe), whereas the GTI are both 7mm. The lines from the pump to the tank will be GTI so that’s fine but I was planning to keep the syncro hoses from the pump to the engine bay – does anyone think the smaller return hose will cause problems??
Had a good look at the syncro exhaust around the bulkhead today – you are dead right Mr. Hell – that ain’t going to flow much, especially where it goes square… [V]
I now understand the bulkhead cutting and shutting – there isn’t much room at all between the steering knuckle shroud and the prop CV – the exhaust would appear to be the big question as you correctly stated.. Could always whack a 1.8t in there – there’s enough room for a 3″ single downpipe….[
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Chris – Grey carpets are both shabby and a bit oil stained..
my syncro currently has a full ‘longlife’ custom stainless system with the stock syncro manifold. The current plan is to use stock parts – i.e. no real performance gains but easier for now but I’m open to suggestions as I go – it wouldn’t harm to come up with a more liberating solution..
As far as wiring goes, I like things to be FAF and will also be incorporating the syncro reverse switch wiring into the GTI engine bay loom but possibly not with multi-coloured tape as it will be on show…[
] Because my conversion isn’t as full on as yours (i.e. it’s much more of a straight swap) there are a lot less issues..
Siemens and Bosch are the same company BTW (well, sort of – Siemens own Bosch)(and Skil and Atco and Qualcast and Blaupunkt and thousands of other companies…)Chris.
#1 – Getting the rod change rod out of the tunnel gearchange housing on a syncro is a NIGHTMARE. I thought I could do it by splitting the rod at the coupler under the car at the front of the tunnel and wangling it out – oh no…
On a standard 2wd GTI – yes, on a syncro – no way – it was exhaust off and lots of pratting around to get the gearchange mechanism to withdraw. The height of the tunnel makes it really difficult. If anyone has an easy way of doing this without stripping the exhaust I’d be more than interested…
Once it’s done though it is fantastic not to have any of those ‘reversed into the guy behind me at the traffic lights again’ style accidents…Chris.
Hi morefire – there are no mechinical parts with the kit I have it’s all of the electric loom, through to the sensors, the ECU, pump & cylinder etc. As I stated, the hub rotors that the sensors monitor are not included.. I’m not sure what the sensors are attached to – can anyone with an ABS rallye shed any light?
The full loom is included with relays etc.
PM me and I’ll send you some photos.Danny – I got an early electrics GTI so it should plug and play into the early (both ’89) fuse box on the syncro – the only bit that will need retaining from the syncro loom is the gearbox reverse switch – I am happy to splice this into the GTI digifant loom to keep the rear diff circuit factory…
Chris.
Thanks Chris – that’s what I thought. Anyone after a full rallye ABS setup (LHD…)??[
]Collected early Mk2 8v GTI on Saturday so will start swapping bits onto syncro tomorrow. Going to start at the back with the fuel pumps and associated wiring and work forwards. GTI has all interior stripped already so is a bit easier to see what’s going on.
Am planning on swapping nearly all of wiring loom over except for reverse switch / diff lock, will remove that from syncro loom and splice it into GTI loom so it’s as original as poss.
Looking for a rallye / passat cable change box (again) if anyone has one kicking around…
Will post photos and problems as I go if anyone’s interested..
Chris.
