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    Thread: 16Valve is Inside - Time For Externals

    1. Member 16ValveInside's Avatar
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      05-15-2011 10:22 AM #1
      Update - 16V Engine & Trans are installed, time for the external bolt on's.
      I am so close to being finished with stuff that has to be cleaned and painted!
      Next step was the starter and alternator. Both of these were working when removed but they were dirty. I thought about just taking them apart and cleaning, but good luck trying to take an alternator apart, so I found a local rebuilder and told them, take em apart, and clean em up. I am in no hurry, they worked before, project car, anything needs to be done inside, do it.
      And here are the results:







      starter installed - after hooking up the engine hoist for support and a jack under the engine just to be safe, hard to get use to having to support the weight of the drivetrain to replace/install a starter



      they did a good job reasonable price and much cheaper than buying a reman Bosch plus shipping.
      plus these are the oe Bosch units to the car.

      Question - What is it that bolts to that little slotted bracket to left of the engine mount?

      91 GTI 16V Project - All Motor - My Build Thread - http://forums.vwvortex.com/showthrea...ssembly-Thread

    2. Member VEE-DUBBER's Avatar
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      05-15-2011 05:07 PM #2
      Knock sensor connector slides in the slot.

    3. Member 16ValveInside's Avatar
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      05-21-2011 09:43 AM #3
      Quote Originally Posted by VEE-DUBBER View Post
      Knock sensor connector slides in the slot.
      thanks, now I know I can take it off since I'm going MegaSquirt
      91 GTI 16V Project - All Motor - My Build Thread - http://forums.vwvortex.com/showthrea...ssembly-Thread

    4. Member 16ValveInside's Avatar
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      07-10-2011 11:45 AM #4
      I finally got a downpipe. I'm going with a complete Techtonics exhaust system, but I could not decide what to do about a downpipe. I wanted to buy theirs but its stainless which I'd love to have but just could not justify the $275.00 price tag for the 251-117S. I found one of the older non stainless versions in the classified but it did not have the flex coupling and the cost of a coupling and the 251-117 would end up being more. So I found the Bosal part number and the searched the net for the best price and prices went from 228.00 and up, but I found a place on E-bay that had 3 in stock for $150.00 so I bought one. This was made in Italy.

      [IMG]Photobucket[/IMG]
      91 GTI 16V Project - All Motor - My Build Thread - http://forums.vwvortex.com/showthrea...ssembly-Thread

    5. Member Eric24v's Avatar
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      10-22-2011 02:37 PM #5
      Updates!!!!!

    6. Member 16ValveInside's Avatar
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      10-22-2011 08:02 PM #6
      updates indeed,

      Got the axles installed, AutoTech has complete Loebro german right side axles on clearance sale for like 110.00 shipped. So I picked one up and then bought a new german inner and outer joints for the left side and reused the original axle, not a big fan of all the new cheap aftermarket axles, but if this was gonna be a stock daily driver they would be probably ok.

      I've started going through the engine compartment wiring, hooking up the starter and alternator, cleaning terminals/grounds and thats where I am now, I'm going to clean/organize/hookup as much of the wiring that I'm going to use.
      91 GTI 16V Project - All Motor - My Build Thread - http://forums.vwvortex.com/showthrea...ssembly-Thread

    7. Member Eric24v's Avatar
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      11-07-2011 10:37 AM #7
      Keep us updated with pics as well... beautiful build (the last thread and this one).


      btw, I have a metal coolant flange if you're still looking for one.

    8. Member 16ValveInside's Avatar
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      11-26-2011 08:21 AM #8
      Quote Originally Posted by Eric24v View Post
      Keep us updated with pics as well... beautiful build (the last thread and this one).


      btw, I have a metal coolant flange if you're still looking for one.
      Thanks for the comments, and as far as the metal coolant flange, I'm just going to go with
      the plastic one on the side of the head since I've already installed it, but I'm using the OE metal one for the front.
      91 GTI 16V Project - All Motor - My Build Thread - http://forums.vwvortex.com/showthrea...ssembly-Thread

    9. Member 16ValveInside's Avatar
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      11-26-2011 08:43 AM #9
      OE drivers side axle after I stalled new german inner and outer cv joints and boots



      And the right side long axle, this is the one I got from Autotech, killer deal, new complete
      german loebro axle, listed on their site under the clearance section. I think I got this for
      110.00 shipped.



      91 GTI 16V Project - All Motor - My Build Thread - http://forums.vwvortex.com/showthrea...ssembly-Thread

    10. Member Road Boss's Avatar
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      11-26-2011 12:16 PM #10
      I need to get one of those down pipes.

    11. Member Eric24v's Avatar
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      11-27-2011 12:45 AM #11
      as mentioned, sick build.

      Why no euro 50mm manifold? I forget which cams you're going with, so if they're the stockers, nevermind..

    12. Member Sr. Karmann's Avatar
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      12-03-2011 07:50 PM #12
      Quote Originally Posted by 16ValveInside View Post
      thanks, now I know I can take it off since I'm going MegaSquirt
      I'm always a huge fan of removing/cutting brackets to save weight, but do have the question. Are you going to run knocksence?

      http://www.viatrack.ca/
      Quote Originally Posted by crazynorweegian View Post
      Good luck, might want to get vaccinated for "while-I-am-in-there" syndrome.
      tek-euro.com SpoonFedTuning

      my Corrado's specs on corrado-database / My Corrado Build Thread / My Cabby Build Thread / My Boat Build: 18' Powerplay w/5.7l V8

    13. 12-03-2011 09:55 PM #13
      I've been running knocksense with ms. Nice to be able to see and log any knock, even when you can't hear it in the car. I have a red led on the dash too just so I can see it happening. I ran a tank of regular gas because I wasn't planning on pushing it, but there was detonation that would happen at certain times until I filled back up with premium. It certainly seems to be an accurate, inexpensive device.

    14. Member Sr. Karmann's Avatar
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      12-04-2011 05:40 AM #14
      Quote Originally Posted by chadr View Post
      I've been running knocksense with ms. Nice to be able to see and log any knock, even when you can't hear it in the car. I have a red led on the dash too just so I can see it happening. I ran a tank of regular gas because I wasn't planning on pushing it, but there was detonation that would happen at certain times until I filled back up with premium. It certainly seems to be an accurate, inexpensive device.
      Quote Originally Posted by crazynorweegian View Post
      Good luck, might want to get vaccinated for "while-I-am-in-there" syndrome.
      tek-euro.com SpoonFedTuning

      my Corrado's specs on corrado-database / My Corrado Build Thread / My Cabby Build Thread / My Boat Build: 18' Powerplay w/5.7l V8

    15. Member 16ValveInside's Avatar
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      12-04-2011 05:31 PM #15
      Quote Originally Posted by Eric24v View Post
      as mentioned, sick build.

      Why no euro 50mm manifold? I forget which cams you're going with, so if they're the stockers, nevermind..
      Thanks,

      I'm running the AutoTech Sport Cams, and I'm using a stock 42mm intake that is in like new condition. I purchased it used from Autotech, it was used on one of their test engines and they purchased it new years ago.

      I don't think the 50mm delivers enough "bang for the buck", all the gains are at high rpms. Plus you get softer low end and not as much torque.
      91 GTI 16V Project - All Motor - My Build Thread - http://forums.vwvortex.com/showthrea...ssembly-Thread

    16. Member 16ValveInside's Avatar
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      12-04-2011 05:33 PM #16
      Quote Originally Posted by Sr. Karmann View Post
      I'm always a huge fan of removing/cutting brackets to save weight, but do have the question. Are you going to run knocksence?

      http://www.viatrack.ca/
      I did not think you needed a knock sensor with a NA Megasquirt install, might be worth checking into, thanks for the link
      91 GTI 16V Project - All Motor - My Build Thread - http://forums.vwvortex.com/showthrea...ssembly-Thread

    17. Member Sr. Karmann's Avatar
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      12-05-2011 08:54 AM #17
      Quote Originally Posted by 16ValveInside View Post
      I did not think you needed a knock sensor with a NA Megasquirt install, might be worth checking into, thanks for the link
      No problem, and it is not required if you wanna play it safe, but to tune to the max it is a real good idea
      Quote Originally Posted by crazynorweegian View Post
      Good luck, might want to get vaccinated for "while-I-am-in-there" syndrome.
      tek-euro.com SpoonFedTuning

      my Corrado's specs on corrado-database / My Corrado Build Thread / My Cabby Build Thread / My Boat Build: 18' Powerplay w/5.7l V8

    18. 07-20-2012 03:30 AM #18
      Quote Originally Posted by Sr. Karmann View Post
      No problem, and it is not required if you wanna play it safe, but to tune to the max it is a real good idea
      Haha i think running the Knocksense would be "playing it safe" regardless if you are going to tune for max power or not. The stock EMS systems on are 16v's have knock sensors for a reason.

      Us NOOB's need all the help we can get but i'm really glad you posted the link (Sr. Karmann). Its cool how you have the option of having knocksense connected to MS. I think i am going to hook up a buzzer instead of a red LED blinking light for knock/ping warning.

    19. Member Aggro Crag's Avatar
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      07-31-2012 03:23 AM #19
      AHH! I just read both your build threads and then.. nothing for 9 months.

      Subscribing, hoping for a megasquirt mega update
      -Zac

      @feces

    20. Member 16ValveInside's Avatar
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      08-05-2012 05:26 PM #20
      working on getting the right fittings for fuel lines right now, got almost everything I need to go from the plastic fuel lines at the firewall (this was a digi II 8V car originally) to the ross fuel rail and then back from the fpr to the returrn line. Got a fuel pressue gauge in there also. update soon.
      91 GTI 16V Project - All Motor - My Build Thread - http://forums.vwvortex.com/showthrea...ssembly-Thread

    21. Member 16ValveInside's Avatar
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      08-19-2012 10:09 AM #21
      Update:
      Got the Bosch Fuel Injectors that I'm using cleaned and tested and Installed.





      Fuel lines - this was a original 91 GTI digi II 8v car and that means it has the plastic fuel lines with the metal insert in the ends. When searching fuel line info I read somewhere on here that somebody used 1/4" fuel injection hose over ths plastic fuel lines with a clamp. No way, its to tight, you might get down far enough to put a clamp on it, but I wanted to get it down to the first bump where the origianl fuel line stopped. to do this you have to use the OE size fuel line which is 7mm ID X 13mm OD, 7mm internal diameter, 3mm wall thickness high pressure fuel line. German Auto Parts has it (of course they do) and its made in germany.

      Next issue is going from OE fuel line to a -4AN fitting, including a fuel pressure gauge, and then ending up at a -6an 180 degree fitting going into the fuel rail, and what a pain it was.

      In the hours it took to find the fittings I needed I found a really cool Earls fuel pressure gauge bracket with a T fitting that I wanted to use because I could also use it to make the transition from -4an to -6an.



      Then the question was where to mount it. After playing around with different locations I noticed this bracket:



      The 2 studs lined up perfectly with the ones for the bracket just had to make the holes a little bigger and the position worked out great.



      The T-fitting that came with the bracket is NPT thread for the gauge and -6AN on each end.
      I used a -6AN to -4AN adapter at the top to a -4AN 180 degree to barb fitting to connect to the fuel line. The clamp at the fitting is a 2 ear Oetiker Clamp.



      The clamp for the rubber line to OE plastic line is a Wurth fuel injection hose clamp. At the bottom I used a -6AN to 90 degree 3/8" barb fitting with 3/8"fuel injection hose that goes to a -6AN 180 degree 3/8" barb fitting at the fuel rail. Both ends of the 3/8" fuel injection hose are secured using single ear Oetiker clamps. -6AN is 6/16" (3/8").





      installed



      Last edited by 16ValveInside; 08-19-2012 at 10:38 AM.
      91 GTI 16V Project - All Motor - My Build Thread - http://forums.vwvortex.com/showthrea...ssembly-Thread

    22. 08-19-2012 08:14 PM #22
      Damn, everything is so nice and clean! I gotta say though, I'm not a fan of the crimp clamps nor the screw clamps (when I'm doing them at least). You could have used something like this to go from the OE plastic tube http://www.fluidsystemsengineering.c...&cat=14&page=6 You just have to make sure you get one for the OD of your tube. From there you could screw straight into your gauge adapter.

      Either way, when done right, I'm sure those crimp bands work. Nice build.

      -Alex

    23. Member 16ValveInside's Avatar
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      09-01-2012 03:56 PM #23
      Quote Originally Posted by 20v_boost View Post
      Damn, everything is so nice and clean! I gotta say though, I'm not a fan of the crimp clamps nor the screw clamps (when I'm doing them at least). You could have used something like this to go from the OE plastic tube http://www.fluidsystemsengineering.c...&cat=14&page=6 You just have to make sure you get one for the OD of your tube. From there you could screw straight into your gauge adapter.

      Either way, when done right, I'm sure those crimp bands work. Nice build.

      -Alex
      thanks, and thanks for the link
      91 GTI 16V Project - All Motor - My Build Thread - http://forums.vwvortex.com/showthrea...ssembly-Thread

    24. 04-17-2013 01:53 AM #24
      How is the MS Setup coming along 16ValveInside?

    25. Member 16ValveInside's Avatar
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      11-05-2013 09:59 AM #25
      Quote Originally Posted by MEGA 16v GLI View Post
      How is the MS Setup coming along 16ValveInside?
      making some progress, I started a thread in the, Carbs, ITBs and SEM Forum, since thats the place to go for megasquirt related questions,
      and just posted some updates there. I got the exhaust and downpipe installed, pics coming soon
      91 GTI 16V Project - All Motor - My Build Thread - http://forums.vwvortex.com/showthrea...ssembly-Thread

    26. Member 16ValveInside's Avatar
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      11-05-2013 10:26 AM #26
      got the exhaust system installed, went with the TT system with the borla muffler



      Bosal Downpipe







      The catalytic converter came from Summit Racing - its a MagnaFlow - Manufacturer's Part Number 22915, same one that use to be sold through Autotech

      Summit Racing Part Number MPE-22915 UPC 841380006509



      installed

      Last edited by 16ValveInside; 11-05-2013 at 10:28 AM.
      91 GTI 16V Project - All Motor - My Build Thread - http://forums.vwvortex.com/showthrea...ssembly-Thread

    27. 04-01-2014 06:31 AM #27
      good build

    28. n00b
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      04-01-2014 10:43 AM #28
      What are you doing for a heat shield for the header and down pipe? You know you WILL melt your tranny bushings in no time like that. And your intake manifold will get so hot, you wont be able to touch it. Hopefully you put the heat shield on the block around the new Cv joints.

    29. Member 16ValveInside's Avatar
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      04-06-2014 08:38 AM #29
      Quote Originally Posted by Project .C. View Post
      What are you doing for a heat shield for the header and down pipe? You know you WILL melt your tranny bushings in no time like that. And your intake manifold will get so hot, you wont be able to touch it. Hopefully you put the heat shield on the block around the new Cv joints.
      I've got the one around the cv joint, you can see it in one of the pictures. The heat shield for the exhaust mainfold and downpipe, is that the one the bolts to the exhaust manifold?
      91 GTI 16V Project - All Motor - My Build Thread - http://forums.vwvortex.com/showthrea...ssembly-Thread

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