[Kav1187]

Ordered the wishbones…hoping the mk2 beam is ok []

[Kav1187]

I’m struggling to find the full set. Found one in South Germany but it’s collection only Thinking that the wishbones might be easier to find on their own if they’ll fit the mk2 beam.

[Kav1187]

Thanks Chris – what about the sensor – is there a hole for it on the standard syncro setup?

[Kav1187]

Ok so to wide track we wouldn’t need the mk3 VR6 beam, we’ll just need the wishbones? I take it these come with the ABS sensor mounts as standard?

[Kav1187]

The bonnet release catch was a direct swap from the S3 and is much stronger than the skinny mk2 one

The S3 handles are also an easy swap – just need to remove the plastic lugs

Let the fun commence…

Good time to do the cambelt

Also noticed when I drove the S3 home it wasn’t running quite right. After a bit of trawling I found there’s a common fault…the crank
case breather pipe tends to split over time

Prop Shafts Out

Old clutch plate was pretty worn

Painted the gearbox just to tidy it up a bit

Turbo Oil return pipe gets in the way of the mk2 mount – to be fixed at a later date

Time to fit the cable shifter

I got hold of a Dutch Build gearbox mount just to save me time and bolted the engine to the mounts as they are

But found it didn’t sit quite square with the subframe which would mean it will sit wonky in the car

I used bits of the S3 for materials to fabricate the front mount using the existing mk2 mount.

Once the front mount was in place, I was able to work out where the gearbox mount needs to sit…the cup needs to be cut and moved quite a bit further back…

[Kav1187]

Engine in the car…

This engine served well for about 9 months of occasional use and it got me through a pretty rough winter. The 4×4 capabilities were amazing!

But….it started going through oil at an alarming rate….luckily I had a litre of oil in the boot which was enough to get me home.

Time for another swap

Enter the donor car

A rear ended S3 – just superficial damage but good enough for the conversion

Stripped out the mk2

My mate Russ giving a helping hand

I started off with installing the recaro leather seats from the S3. First job was to drill out the runners from the S3

And cut out the front mount for the seat

Then to weld them in

Passenger side too

I later found out that the S3 seats would have bolted directly onto a MK2 recaro frame. Ah well it’s done now lol.

Where I took the paint off to weld, I first primed the area with magnesium primer – this allows me to protect the metal underneath whilst being able to weld over the top

Rear seats….removing the brackets from the S3

Then into the mk2

Side pivot brackets for the upper seat rests – to be fitted at a later date…

How it will look when complete

[Kav1187]

Thank you for your fast reply – as ever!

Am I able to fit the ABS ring to the disc and if so, is there a way of getting the sensor to mount in the right place?

Thanks,
Kav

[Kav1187]

Hey Chris!

I’ll be looking to fit rear discs to my Syncro during the conversion. One bit I wasn’t sure about was whether I need to use the mk4 carriers for the mk4 caliper or if it’s the mk2 carrier with mk4 caliper?

And is it still the 1.05l disc that is used?

Cheers,
Kav

[Kav1187]

Ps any idea if there are longer starter motor bolts that usually support the front mount? The ones on the 02m gearbox weren’t designed with a front mount in mind so don’t have enough thread poking through on the engine side.

[Kav1187]

No…just bolted it on for now. I didn’t really understand why it had to be cut and moved as it all bolted up ok…but i guess it’s to move it back. DOH! Tthanks for the replies guys, I think I know what I need to do now I’ll start a build thread when i get time to upload all the pics

[Kav1187]

Hi Chris, the previous gearbox was an 020. was the rear engine mount different on the 02c engines?

[Kav1187]

Thanks bud, I’ll get one ordered tomorrow and see if that works []

[Kav1187]

Thanks for your prompt replies

I’ve had a look at the relay. The one that clicks when I engage reverse is numbered 83 P/N 191 957 917. I’ve noticed that it doesn’t turn back off when I come out of reverse – it’ll only click ‘on’ but not ‘off’. To reset it, I have to turn the ignition off. Is this how it’s supposed to behave?

I tried to reverse up a slippery kerb…the first attempt, the relay clicked and it pulled me up. Second attempt (without resetting the relay) the front wheels just spun without 4×4. Third attempt (after I reset the relay)the relay clicked but the front wheels still spun and didn’t engage the 4×4

Is it the relay still? It’s too snowy outside to jack the car up to have a look at the rear diff.

[Kav1187]

Hi Folks…I’ve got a similar problem. The reverse lights didn’t work and I had no 4×4 in reverse.

I took the switch apart and fixed it so the reverse lights come on now…I made sure all the other connections inside the switch were working properly too, so I know that’s not the issue.

I’ve given the light green pipes a BJ and they all seem to be passing air, so they’re not blocked. The 4×4 does engage in reverse, but only 1 in 10 times…and usually not in the snow when I need it most

Any ideas?

Cheers,
Kav

[Kav1187]

Don’t quote me on this but I think each side draws between 20 and 30 amps so I don’t think you want to be sending too much current through the windscreen otherwise you’ll start melting the thin wires. I think that this is why the wiring is split in two on the windscreen.

The 2 live feeds/relays were recommended to me by the company that supplied the windscreen so that’s good enough for me.

Anyhoo…to answer your question – yes!!! It’s 110% worth it! It makes life sooo much easier in winter, the snow/ice just melts off in a couple of minutes. I’m tempted to get one for the syncro as well.

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