Professional Restoration 

 


of

83 VW

USING

   

GENUINE PARTS

 


New VEGE (VAG) DX engine.

83 VW  was professionally restored during the Summer of 2004. This genuine Campaign GTI has a known service history until 1995, before being purchased by myself, for the second time, in 2001. Although registered as having eight owners, technically it is only five, as the car was sold within the same two families. All previous owners looked after the car and kept it largely original. A BBS front spoiler, VW tow bar and sports exhaust were fitted in the early 1990s. 

Sadly, the car fell on hard times between 1999 and 2001 and its future looked uncertain.

 In March 2004, the vehicle underwent a full appraisal prior to restoration. After professional buffing, the original paintwork is now in superb condition for a car over 20 years old. Unfortunately, the same could not be said for the engine and running gear. After almost 200,000 miles completed, tests revealed the original DX engine was showing signs of wear and action would be needed sooner rather than later. Reconditioned engines from various UK suppliers did not appear to be the best available. Eventually, a remanufactured DX engine was sourced from VEGE in Holland.

All VEGE engines are hot run tested for 30 minutes.

VEGE website: http://www.vege.nl/EN/

VEGE engines are remanufactured, not reconditioned, and are built to the exact specifications, and with the same components, as specified by the original car manufacturer. Each VEGE engine is hot run tested under its own power for a minimum of 30 minutes before shipping. VEGE are a respected well established company and supply one major European car manufacturer with replacement warranty engines. The 5 speed gearbox was rebuilt with a new gear pack and seals by Central Axles, Birmingham.

VEGE engine label.

 

New GTI decals.

On strip down, it was found that the overall body condition was very good with just a few rust patches on the underside. Corrosion around the sunroof tray and tailgate lock was repaired. An approved Golf Mk1 towbar had been professionally fitted and was retained. 


"... reconditioned engines from various UK suppliers did not appear to be the best available. Eventually, a remanufactured DX engine was sourced from VEGE in Holland."

 

The car kept its 100% original panels and the paintwork will remain as supplied from Wolfsburg although various trim, decals and new bumpers were fitted. To give the vehicle a more purposeful stance, a set of Ronal R10 alloys wheels with 195/50 tyres were fitted together with a front a rear strut brace. A Jetex exhaust completed the picture.

Complete details of restoration, listed below.

Engine, ancillaries and gearbox removed - original paintwork retained.

 

VEGE - the best replacement engines available.

 

Correct factory parts identified and sourced.

 

Sourcing correct parts - very time consuming.

 

New VAG (Bosch) fuel metering head.

 

New fuel accumulator and bracket.

 

New fuel pump bracket and absorber.

 

New fuel tank sender seal.

 

Rubber sump pan gasket.

 

Oil filter housing gaskets.

 

New rubber seals etc.

 

Lots of small insignificant parts.

 

Replace those perished rubber grommets!

 

More genuine VAG parts.

 

New front assembly.

 

New fuel tank.

 

New brake compensator.

 

New front suspension wishbones.

 

Underside comprehensively undersealed.

 

Rebuilt gearbox bolted on to new engine.

 

All new bushes, bolts etc.

 

Jetex exhaust - a tight fit.

 

All ready for the road.

 

Mechanical rebuild complete.

Restoration of 83 VW

(Started: June 2004 - Completed: November 2004)

All work professionally undertaken.

  • Carry out manual compression test of installed engine

  • Remove engine and gearbox (lower from chassis)

  • Remove all ancillaries from vehicle

  • Remove road wheels and rear suspension/brake set-up

  • Remove steering rack and front suspension/brake set-up

  • Remove engine/cooling system and auxiliary pipe work

  • Remove underbody cables etc.

  • Remove exhaust and ancillary brackets

  • Remove fuel tank

  • Pressure wash / degrease engine compartment and underside

  • Check condition of underbody and repair as required

  • Repair corrosion to sunroof tray seam (both sides)

  • Repair corrosion to spare wheel well

  • Repair corrosion to o/s rear seat belt mounting area

  • Repair corrosion to o/s/r wheel bay

  • Clean underbody and repaint with underseal

  • Re-wax lower engine compartment (WAXOYL)

  • Fit new VEGE (DX) remanufactured engine 

  • Rebuild 5 speed gearbox with new gear pack

  • Build up engine with new components including distributor and water pump (all VAG)

  • Fit new rubber hoses (VAG complete set)

  • Renew entire fuel injection system (including Bosch meter head)

  • Fit new fuel tank

  • Fit new brake master (and new brake light switch)

  • Fit new drive shafts (VAG complete)

  • Check wheel arch clearance for 15' wheels

  • Remove front plastic wheel arch liners and check / repair corrosion

  • Prepare and repaint wheel arch wells and apply anti chip coating (3M)

  • Repaint suspension components

  • Apply anti chip protection to all wheel arches (3M)

  • Repair and re-weld clutch cable / bulkhead aperture

  • Supply and fit new fuel pipes (as required) (VAG)

  • Supply and fit new brake pipes (VAG)

  • Refit suspension subframes / new components

  • Supply and fit standard spec road springs (BOGE)

  • Supply and fit standard spec shock absorbers and auxiliaries (BOGE)

  • Supply and fit standard spec front brake discs and pads

  • Fit new front brake disc callipers

  • Supply and fit new wheel bearings (VAG)

  • Supply and fit new rear brake drums (VAG)

  • Supply and fit new Bosch cambelt

  • Supply and fit new complete cambelt cover x2 (VAG)

  • Supply and fit all new braided fuel lines (complete set)

  • Supply and fit 4 new Bosch fuel injectors and seals

  • Supply and fit new engine breathing apparatus

  • Supply and fit new alternator (BOSCH)

  • Supply and fit new alternator mounting bracket (VAG)

  • Supply and fit new steering track rods (VAG)

  • Supply and fit new heater matrix (VAG)

  • Supply and fit new heater regulator (VAG)

  • Supply and fit new clutch (OEM)

  • Fit supplied new radiator cowling (VAG)

  • Fit supplied radiator air ducts x3 (VAG)

  • Supply and fit new cooling fan (dual speed) (GSF)

  • Fit supplied VAG battery

  • Fit new coolant and brake fluid reservoir containers (VAG)

  • Supply and fit new radiator (VALEO)

  • Fit supplied new thermostat (VAG)

  • Supply and fit clutch cable (VAG)

  • Supply and fit throttle cable (VAG)

  • Supply and fit speedometer cable (VAG)

  • Supply and fit new dual-tone horn (VAG)

  • Supply and fit new engine mounts x2 (VAG)

  • Supply and fit gearbox mounts x2 (VAG)

  • Supply and fit suspension bushes (VAG)

  • Fit supplied new inner and outer driveshaft boots x2 (VAG)

  • Supply and fit new earth cable (VAG)

  • Fit supplied steering rack rubber boots (VAG)

  • Fit supplied VAG HT leads (VAG)

  • Fit supplied wheel arch trim x4 (GSF)

  • Fit supplied engine bay (bulkhead) rubber seal (VAG)

  • Fit supplied front Hella spotlamp grille

  • Fit supplied new headlights (HELLA)

  • Remove all radio aerial apparatus/door speakers

  • Fit supplied Jetex sports exhaust (complete system)

  • Fit reinforced exhaust mounts

  • Fit supplied upper aluminium front strut brace

  • Fit supplied aluminium rear strut brace (TRIMSPORT)

  • Fit new wiper motor (VAG reconditioned)

  • Fit supplied new door window seals (VAG)

  • Fit supplied new door seals (VAG)

  • Fit supplied front door waterproof membrane x2 (VAG)

  • Remove rear window and fit new black decal to rear hatch (TRIMSPORT)

  • Refit rear window with supplied new seal (GPC)

  • Supply and fit wiper blades x3 (BOSCH)

  • Repaint all tow bar apparatus

  • Check fuses and fit new fuel pump relay (VAG)

  • Fit new fuel tank sender unit and seal (VAG)

  • Fit new fuel pump bracket and absorber (VAG)

  • Fit new fuel accumulator (BOSCH)

  • Fit new fuel accumulator bracket (VAG)

  • Fit supplied fuel filler neck (3rd PARTY STAINLESS)

  • Fit supplied rear parcel shelf (eBAY)

  • Fit supplied new wooden door cappings (Rokee)

  • Fit supplied front number plate holder (VAG)

  • Fit new Ronal Turbo (R10) alloy wheels (ET37) and 195/50/15 tyres

  • Supply and fit all new remaining service items

  • Carry out 4 wheel alignment check

  • Bosch tune engine

  • Check for fluid leakage

  • Carry out MOT test

  • Road test vehicle and rectify snag list

AFTER 500 MILES COMPLETED:

  • Drain off 'running in' engine oil

  • Refill with new oil (CASTROL)

  • Replace oil filter (VAG)

  • Drain off gearbox oil and renew (CASTROL)

  • Check wheel alignment

  • Check engine, cooling system and gearbox for leakage

  • Run engine on analyser

  • Rectify 2nd snag list 

*VAG = genuine Volkswagen/Audi dealer sourced parts.

 

Full inventory and costing of restoration.