Caddy Van VR5 Conversion
Discussion
jkh112 said:
I enjoy reading about projects like this, keep us updated.
Why fit a VR6 gearbox, what is wrong the V5 gearbox?
The gearing in the V5 'box is no good for 15 inch wheels. Most V5 Golfs have 16 or 17 inch wheels which means the van would have rapid acceleration but would be revving its tits off on the motorway etc. The VR6 'box is much more suited to the smaller wheels. Why fit a VR6 gearbox, what is wrong the V5 gearbox?
Can’t understand why your using an O2O VR6 Box when the V5 O2J is a better box, and has the updated O2J shifter tower installed? You would then need a shifter assembly from a Caddy TDI, Ibiza Cupra and your good to go.
You’ll need VR6 mounts all round they should bolt on to the block, I can’t remember what front mount bracket to use tho
Good project, converted one to a VR6 some years ago
You’ll need VR6 mounts all round they should bolt on to the block, I can’t remember what front mount bracket to use tho
Good project, converted one to a VR6 some years ago
martin mrt said:
Can’t understand why your using an O2O VR6 Box when the V5 O2J is a better box, and has the updated O2J shifter tower installed? You would then need a shifter assembly from a Caddy TDI, Ibiza Cupra and your good to go.
You’ll need VR6 mounts all round they should bolt on to the block, I can’t remember what front mount bracket to use tho
Good project, converted one to a VR6 some years ago
I've answered this above. The V5 gearbox isn't geared correctly for the 15inch wheels I'm running. You’ll need VR6 mounts all round they should bolt on to the block, I can’t remember what front mount bracket to use tho
Good project, converted one to a VR6 some years ago
It was still light when I got home from work this evening so I spent an hour on the van.
I don't have the wiring expertise to sort the Loom for this so someone is doing it for me. Annoyingly on these the Loom goes all the way behind the dash which means dash out to extract it! This evening I started taking off all the bits and bobs to get the dash out.
I don't have the wiring expertise to sort the Loom for this so someone is doing it for me. Annoyingly on these the Loom goes all the way behind the dash which means dash out to extract it! This evening I started taking off all the bits and bobs to get the dash out.
Decided to finish getting the loom out this afternoon.
What absolute pig of a job! The whole dash has to come out because it runs along the bulkhead. It's done and out though
It's all packaged up ready to go and be spliced with the V5 loom and I've also got the ECU packaged to be sent to someone else to have the immobiliser, EGR, secondary air pump and other codes removed from it
What absolute pig of a job! The whole dash has to come out because it runs along the bulkhead. It's done and out though
It's all packaged up ready to go and be spliced with the V5 loom and I've also got the ECU packaged to be sent to someone else to have the immobiliser, EGR, secondary air pump and other codes removed from it
Got some more done today.
Got the van up on axle stands. Ideally a little higher would of been nice but this is all my poor Halfords trolley jack could manage. Just about leaves enough space underneath for me to work above my head
Once it was in the air I proceeded to get the front struts, hubs and lower arms off. Amazingly it all came off without too much of an argument which made my life easier
I decided to see how easily the wishbone bushes would come out. That required the standard method of FIRE!! I've got some Powerflex bushes for the front end so I'll press them in during the week
I then got the downpipe/cat off. I'm hoping to reuse the cat for the new exhaust.
Once the exhaust was off I also took the gear linkage off. The van currently has a rod linkage but I've got a cable linkage from a Mk4 Golf to go on instead. I also spent some time trying to figure out how to get the accelerator pedal and bar out so I can fit the DBW pedal. I didn't get any pictures of this because I suddenly realised the time and needed to take my Daughter to a birthday party (which is where I am now!)
Got the van up on axle stands. Ideally a little higher would of been nice but this is all my poor Halfords trolley jack could manage. Just about leaves enough space underneath for me to work above my head
Once it was in the air I proceeded to get the front struts, hubs and lower arms off. Amazingly it all came off without too much of an argument which made my life easier
I decided to see how easily the wishbone bushes would come out. That required the standard method of FIRE!! I've got some Powerflex bushes for the front end so I'll press them in during the week
I then got the downpipe/cat off. I'm hoping to reuse the cat for the new exhaust.
Once the exhaust was off I also took the gear linkage off. The van currently has a rod linkage but I've got a cable linkage from a Mk4 Golf to go on instead. I also spent some time trying to figure out how to get the accelerator pedal and bar out so I can fit the DBW pedal. I didn't get any pictures of this because I suddenly realised the time and needed to take my Daughter to a birthday party (which is where I am now!)
Managed to get the cable throttle pedal out after work this evening. Had a go at lining up the DBW pedal from the Mk4 Golf but I can't see an obvious way of making it fit! I've been advised to use a DBW pedal from a Caddy TDI but they're like poor quality wobbly children's play pony poo so that's kinda stopped me in my tracks for now! I'm currently waiting for the engine and gearbox mounts to arrive, gear linkage and I'm trying to get the inlet off the V5 engine so I can unplug the injectors and get the Loom sent off to be modified. So much to do and so little time!
Another small update.
I got out there this morning and got the front subframe off so I can get the ARB off. I've got some Powerflex ARB bushes on order so when they arrive I can get it all back on again. I've been lucky so far in that everything has come undone easily
I also managed to buy a black dash from a Seat Cordoba this week. I'll still have to dye my grey glovebox lid and do something with the grey door cards but this dash is in much better condition than the grey one
I got out there this morning and got the front subframe off so I can get the ARB off. I've got some Powerflex ARB bushes on order so when they arrive I can get it all back on again. I've been lucky so far in that everything has come undone easily
I also managed to buy a black dash from a Seat Cordoba this week. I'll still have to dye my grey glovebox lid and do something with the grey door cards but this dash is in much better condition than the grey one
My first job at a motor factors had one of these as a spare van. I loved that thing! Every bush was knackered so it rolled like a cruise liner and at the speeds I drove it it drunk fuel. It also used to eat gearboxes and clutches. Apparently at some point before my time the head gasket had gone and it had been skimmed but it went like a rocket compared to the Kangoo poo we had as normal Vans!
Cfnteabag said:
My first job at a motor factors had one of these as a spare van. I loved that thing! Every bush was knackered so it rolled like a cruise liner and at the speeds I drove it it drunk fuel. It also used to eat gearboxes and clutches. Apparently at some point before my time the head gasket had gone and it had been skimmed but it went like a rocket compared to the Kangoo poo we had as normal Vans!
Haha yeh that's probably my first recollection of Mk2 Caddys, seeing the GSF (or German & Swedish as it was called then!) drivers ragging the poor vans around!This morning we took the boys Karting (in the rain) and then went for lunch. This afternoon was earmarked for van work. However, in typical bank holiday fashion it continued to piss it down for the rest of the day!
Not wanting to waste an entire free afternoon I decided to try and get the knackered old bushes out of the wishbones. That meant a trip to Wickes for some M8 threaded rod, big washers and some nuts. 15% off today so that was good
I got home, selected some suitable sized sockets and set to work. My effort lasted at least 20 minutes before the thread stripped on the threaded rod
So off I went to Wickes again and picked up some M10 threaded rod, thicker washers and more nuts. Round two was more successful and I got one of the bushes out in about twenty minutes. Enthused by my progress I got straight on with the other arm and promptly stripped the thread on the rod! The bush was about half way out at this point but wasn't budging any further. By this point I'd lost my patience and got the blow torch out. It took about 10 minutes of intense burning for the metal sleeve to drop out and then I was able to push the burnt bit of rubber out.
With the two trips to Wickes that was my entire afternoon used up! Better than sitting around the house I guess.
In my frustration I forgot to take any more pictures so here's the only one I took.
Not wanting to waste an entire free afternoon I decided to try and get the knackered old bushes out of the wishbones. That meant a trip to Wickes for some M8 threaded rod, big washers and some nuts. 15% off today so that was good
I got home, selected some suitable sized sockets and set to work. My effort lasted at least 20 minutes before the thread stripped on the threaded rod
So off I went to Wickes again and picked up some M10 threaded rod, thicker washers and more nuts. Round two was more successful and I got one of the bushes out in about twenty minutes. Enthused by my progress I got straight on with the other arm and promptly stripped the thread on the rod! The bush was about half way out at this point but wasn't budging any further. By this point I'd lost my patience and got the blow torch out. It took about 10 minutes of intense burning for the metal sleeve to drop out and then I was able to push the burnt bit of rubber out. With the two trips to Wickes that was my entire afternoon used up! Better than sitting around the house I guess.
In my frustration I forgot to take any more pictures so here's the only one I took.
I got home early from work this evening so thought I'd have another look at how to fit the Mk4 Golf accelerator pedal. I think I've figured out a position for it to sit in but I need to get a small box fabricated to bolt it to. Unfortunately I have no idea how to fabricate anything so this is going to be an interesting part of the build! This is the space I have to make something up. I'll be utilising the 3 studs sticking out of the bulkhead to bolt the box down. I'm going to start off with some card to get the shape right and then I'll have to ask someone really nicely to make it out of metal for me.
Oh, I might of forgotten to mention that I need to have this finished before the weekend of the 19th-20th May. That weekend is the Retro Rides Weekender which I have camping tickets for and also a slot of track time as well. I got the track time email this morning which set off a bit of panic haha!
Gassing Station | Readers' Cars | Top of Page | What's New | My Stuff