Vw Caddy Van VR5 Project - We have 3 pedals!

Got some more done today I got out there nice and early while it was still cool outside.

I started off with torquing up the front subframe bolts (I'd left them loose until I was certain I didn't need to take it off again). Then it was time to crack out the wire wheel to clean up the front hubs. I swear the previous owner used to park the front end of this in the sea every night. It all seems to have a coating of rust but only on the front end. After some wire wheel action they looked much better.




Once they were done it was time to get them bolted back on. I'd bought two new lower ball joints but these ones were still in good condition so I've got some spares now






Now it was time to unpack the AP coilovers I bought a couple of months ago. When they arrived I put them in the boot of my car and left them there until today. For all I knew the package could of had a load of house bricks inside :laugh: Thankfully upon opening the packaging I was greeted by a set of coilovers :thumbup:



I was also pleasantly surprised to find some brand new top mounts fitted. Again, I had bought new ones so I've got spares of these too. Obviously I'm only going to be using the front shocks so the rears are going on eBay later.

I got them fitted up nice and easily and stood back to admire my handy work.




Next thing to unpack was the VR6 calipers and carriers. Apart from the crappy paint job they're in good condition and everything is free moving. I gave them a quick going over with the wire brush just to take the surface curse word off anyway. I also unpacked the EBC 280mm brake discs and got them bolted on along with the caliper carriers :thumbup:




Annoyingly my brake pads were meant to be here yesterday and didn't turn up, so I packed everything up and went out to buy some biltong and a new pair of running shoes When I arrived home my brake pads were sat on the doorstep! Typical! I'll get them fitted tomorrow and then go to get my tyres fitted to the wheels so I can drop it back onto the floor Before doing that I'll need to wind the coilovers up a little because they're really low at the moment!

Oh, I managed to edit the qualifying video from Mondays karting sesh last night. Here it is if anyone is interested.

Made a couple of purchases today

First off is some retro audio! I always wanted one of these when I was 17 but couldn't afford one. I know they're not exactly cutting edge when it comes to sound etc but at the end of the day it's a van! For those of you that haven't seen one before it's a JVC Chameleon. The key pad retracts and you have a completely black and smooth front when it's off. Simple things haha.



My second purchase was a replacement steering wheel. It's from a 6N2 model Polo which is about 2000 onwards. They're a straight fit onto the Caddy and look a hell of a lot better than the original.



Ive bought a couple of other things but I'm not sure if they're going to arrive so I'll hang fire on announcing them.

Awesome project! Always fancied a vr6 van, but as you've said, the vr6 engines are starting to fetch higher prices

Think I'd have went the caddy route, if I didn't end up going for a kangoo

Shame it didn't make it to the Weekender, but I'm sure I'll see it at RRG?

Today I got loads done!

I started off routing the engine bay wiring loom. This had all had to come out and be adapted for the new engine. Seeing as there wasn't going to be much room to manoeuvre once the engine was in I figured I should get this done first!





A couple of parts will need to be extended to reach whatever they're meant to be plugged in to and then I can finish wrapping the exposed wires.

Oh, I forgot to mention that the work inspector turned up at this point to make sure I was doing it properly and not cutting any corners! I'm awaiting her results!!!



Once that was done it was time to drag the engine into the open and get it ready to go in

The first thing I needed to do was remove the downpipe and exhaust heat shield. The downpipe is completely the wrong shape to fit the van, however I've got one from a Mk3 Golf winging its way to me that is the same fitment and should be a closer fit on the van, or will at least be easier to adapt to fit. Anyway, four of the six nuts came undone nice and easily. The last two snapped the studs Annoyingly they were coming undone to begin with and then without any warning just snapped. This meant getting the drill out and drilling the studs out.

I managed to drill out the majority of the first one before needed to resort to the die grinder to get the last of it out.







By the time I got to the second one I had a load of blunt drill bits. I got as far as I could with them and then gave up and cracked the die grinder back out. The second one didn't look as pretty by the time I'd finished with it but it will accept a bolt now which is all I need it to do







Once that was sorted I moved on to refitting the engine loom. Thankfully I'd labelled it all up before removing it so it only took a short while to get it refitted



Now it was time to lift the engine off the stand where it's been living for the last few months.



I then lowered it onto some blocks of wood and proceeded to fit the clutch and then the VR6 gearbox. As I've mentioned before I do all this by myself with nobody here to help me, so I forgot to take any pictures of this stage. However, it all went on nice and easily and before I knew it I had an engine and gearbox pretty much ready to test fit into the bay. Annoyingly the front engine mount I bought from eBay was the wrong one and wont even entertain the idea of fitting at all so armed with the gearbox mount, the trolley jack and some blocks of wood I decided to go for it anyway!









It fits!!! Just! It's pretty tight in there and I'm definitely going to have to take it out again to move a couple of things, but it fits. I got the gearbox mount done up, propped the front of the engine and 'box with a piece of wood and shoved the trolley jack underneath to steady it. At this point a delivery guy turned up with the V5 engine cover so of course I had to fit it



Just as I fitted that the heavens opened so it was time to pack up for the day. I got everything cleared away and closed the bonnet, only to find this!



I'll worry about that another day haha!

It does drop down enough to shut the bonnet, the block of wood has the front tilted up further than it would be (Depending on which mount you end up using, assuming an 02a one to match the gearbox, if you still feel its too close you can shorten the mounting on the front crossmember)

The front mount arrived today

I was at work this morning and got home to find my Daughter has chicken pox. That means all my plans for the weekend are out the window and I might get some time to do more to the van

Watch this space!

If you had gone for 16's i have a set of seat wheel trims lol

My Daughter has fallen asleep so I figured I'd get back out there and see about fitting the front engine/gearbox mount so I can remove the block of wood

However, I can only assume I'm being a bit thick because I can't fathom where exactly it's meant to bolt on! The mount has 3 holes, 2 of which have captive nuts on the left side!

Have a look at the pictures and if anyone can make it obvious to me it would be useful. Just to confuse issues I've had to remove the oil cooler because it fouls the mount so even after I've figured out where the mount it meant to sit I've still got to trim it up a bit anyway!











Any advice is welcome!