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I have done a bit of digging online and found this wiring diagram:
It appears to match everything on my car.
This mysterious black wire hanging in my engine bay leads back to 6/15 on the relay in the diagram. there are two black wires coming from 6/15 in my car, the other heads to plug K8 on the fusebox. However I am still no closer to figuring out where the black wire would have been attached to originally.
I suspect it may have been cut to splice in wiring for a trailer socket with reverse lights perhaps…. But that doesn’t answer my question.
BTW the reversing light plug on the gearbox appears original. It has the following wires, brown, white, white/green, black/red and black/blue.
Searching google images I found an image that lead me back to this site:
http://www.vwsyncro.co.uk/data/forums/topic.asp?TOPIC_ID=2162&whichpage=6
ld50 has a useful guide that shows how to modify the two pumps, to make one pump. I reckon I will do what he suggests.
Ok I see that I can get the pump to work with the deeper tank by lengthening the piece of rubber hose it is crimped to the assembly with, that would sort the fuel pickup issue. Then I am left with the level sender issue. I could bend and make up a longer wire arm, however with the longer arm I fear it may foul the side of the tank when it floats up to the top with a full tank of fuel to due its extra length.
Sounds nice, I think I remember seeing it at the Limerick VW show one of the years, extremely mint car on steelies, amazing paintwork. I had my Jetta syncro at the show that same year.
My jetta is going into the garage shortly now for its PG transplant
I will be doing everything you have to do, lift pump, extended fuel lines etc. If I have them in before you I will let you know how it went.
Yes exactly, although the lines from the main underfloor pump back to the fuel tank will have to be lengthened to reach up the extra distance to your syncro fuel tank, but everything from the main pump forward is standard G60/Golf GTi digifant hardware AFAIK, I’m sure someone will correct me if I’m wrong.
BTW where in Ireland are you from? What is your golf syncro like, colour? UK spec 5 door?
The tank won’t be of any use, the boot floor is a different shape. You don’t need to change the fuel tank to convert to g60, just add the lift pump(Extend a GTi pump or use rallye lift pump) and main underbody pump, fuel lines and wiring to your existing car. This is what I am doing at the moment.
I bought acoustic foam insulation that goes under timber flooring. I glued them a few layers together until they were 10-12mm thick and cut them to fit, very light and appears to make a difference to road noise
Hi Chris,
Thanks for the info. So what clutch can I use for a g60 flywheel and rod change box?? Is my only option a standard syncro clutch?
Nothing new for a while I am afraid. I am putting the finishing touches to my ur quattro before I can start this project.
I have the jetta looking very standard at the moment.
I have replaced all the indicators with standard orange lenses and removed the non tinted tail lights for standard rear tails.
I have wound the height back up to a far more subtle drop.
I have put a GTi chin spoiler on it.
I have a blue ultraviolet GTi interior to go in.
I also have a G60 engine for it.
I am on the lookout for a rallye gearbox.
