mk2 16v..she lives! and back with a new look!

How do I swap the clutch/flywheel over to the new block? I can see the bolts that hold the box onto the block, is it just a case of undoing these and the clutch will stay in the box? also, can I just unbolt the driveshafts before i take the engine out and will they just pull out of the gearbox ok? easy to re-fit? one last thing, what order do I need to torque up the head bolts and to what torque settings? cheers:cheers:

Remove the 6 bolts in each shaft at the gearbox, they are m8 spline drive bolts btw. The shafts will then be disconnected.

The gearbox has 2 19mm bolts at the top and 1 19mm at the back near the gearbox dif. obviously your starter motor needs to be removed aswell.

There should also be a couple of covers held on by either a 10 or 11mm bolts. 2 holding the bottom plate and 1 at the back holding the small plate.

Once box is off, you'll see the flywheel on the block.

To remove you'll need a 9mm multi hex socket to undo the 9 bolts.
When the flywheel is off, the clutch plate will fall out too.

Remove the big C clip off the cover and you'll see 6 bolts holding the pressure plate to the block.

Torque the head bolts up in a zig zag pattern. Haynes manual comes in handy for the settings as you torque them once at 1 setting then again at the final setting.

hope that helps

nice one cheers for that! m8 spline drive? is that another tool i'll need to buy?

cupra16vgeezer wrote:

nice one cheers for that! m8 spline drive? is that another tool i'll need to buy?

Yup, ask at a tool shop if you not sure what it looks like. You may have to buy a set of them though depending on who stocks them.

When you have the tool, tap it into each bolt as you go, it'll force the oily grease out and stop it from slipping. Rounded shaft bolts are a pain in the a55 so take ya time.

nice one yoof! thanks again!

head bolt torque spec is as follows :

40nm
60nm
turn 90 degrees
turn 90 degrees

and do it in this pattern

dude, i cant believe you have blown it up already lol!
u gettin there with puttin the new bottom end in then?

i have sorted the ibiza now and is back on the road,

Yeah! I think the oil pump went tits up by the looks of it! new bottom end arrived this morning. just got to get hold of the torx bit for the head bolts and an M8 spline drive bit for the gearbox. my aim is to make this months meet!

Tiz, nice one cheers for that info, did I mention I love you :flower:

cupra16vgeezer wrote:

Yeah! I think the oil pump went tits up by the looks of it! new bottom end arrived this morning. just got to get hold of the torx bit for the head bolts and an M8 spline drive bit for the gearbox. my aim is to make this months meet!

Tiz, nice one cheers for that info, did I mention I love you :flower:

once or twice yeah You gonna get the head skimmed or not bother? If your not flat the block surface and the head surface off with a bit of 800 grit wet and dry and some soapy water as the metal gasket doesnt quiet take up little dips as easily as the fibre one, also make sure you put the sandpaper on a block dont try and do it just with your hands.

nice one fella cheers for that! are the bolts that hold the gearbox onto the block definately that M8 sline thingy? just checking before I buy the tool really!

yeah im pretty sure it is, make sure you get the 12(i think?) point spline one though not the 6 or whatever

what spline are we talking about here?

surely all the bolts that hold the box to the block are normal 6 sided heads ranging from at a guess 15mm to a 19mm head.

then the driveshafts are the little star headed thingys, 6 on each driveshaft.

are the driveshafts not allen bolts then?

Fook sake lol

M8 spline drive bolts hold the driveshafts to box
19mm bolts hold box to block

M12 spline are the head bolts

it's gripped, it's sorted:lol!: that's cleared that up! cheers:cheers:

just had suggestion made to me, would it be easier for me to undo the drishafts from the wheelhubs rather than from the box?

Yes, you'll have too take out the two bottom bolts from the shock, which is still a hundred times easier .....


If you havnt got this done before next weekend i'll pop over and give you a hand....

legend! I need to wait till all the new bits arrive yet so I pobably will end up doing it next weekend tbh. I have to say, looking at the (lack of!) room around where the riveshaft are bolted to the box they look like they'd be a real pain in the arse! so to remove the shafts from thehub I take it's;

Remove wheel
remove caliper
remove brake disc
unbolt shock
undo diveshaft

Ideally,with the car on he ground the first job is too crack the driveshaft nut ,can be a right pain if you do it later on...
Then jack up and remove the wheel and then the shock... dont need to remove disc or caliper

oh right I see! it's not behined the brak disc then? the last car I had to undo the driveshaft on was a rover 600:affraid:

Its the large hub nut mate.

You'll need the car on the ground to undo it with a breaker bar unless you have an airgun at hand thats man enough to do it whilst its still in the air.

Like rolf says, you'll need to remove 1 of the lower shock bolts and loosen the other so the hub has enough movement for the shafts to drop out as you pull on the engine/box.

I'll be down huntingdon later so if i get 5 mins, i'll give you a call and pop round to you to advise

tbh i wouldnt start trying to reinvent the wheel mate. Do it the easy way and just undo it at the box end.. its MUCH easier than fooking about at the wheel side and makes taking the engine and box out easier. There is a reason everybody takes them off the box i tried taking them off the hub end once thinking it would be "easier" and it was a pain in the ass.

tbh tiz I think i'm gonna stick with undoing the shafts from the box. my car is very low to the floor and access to the back of the hubs is very limited and as i'll need to jack my car up anyway I may as well just undo them at the box as they're easier to get to. nearly had an inpromtu engine removal today! thought i'd remove the starter then as the last bolt went tight I realised the hold the engine to the engine mounts! doh!

you should have bought the really long tool from GSF for the shafts you an take them off without even getting under the car

would have done mate but my budget ran out 50 quid ago! why does baby stuff cost sooooo much! managed to borrow one from a lad off all dubz.