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Thread: Mk2 Caddy VR5 Build

  1. #1
    Join Date
    Aug 2008
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    Epsom, Surrey
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    Mk2 Caddy VR5 Build

    It's been a long time since I actually committed to a proper project. I've got my Mk2 XR2 waiting patiently in my garage to be welded back together but I still haven't built up the enthusiasm to start on it haha. I don't want another year of doing nothing car related so hopefully this will suffice.

    I've owned this Mk2 Caddy for a couple of years. It was bought for me to drive around the country when I was Karting so I could sleep in the back of it. It served its purpose for a year very well (apart from a tyre blowing out at 70mph on the M6!) and then got demoted to a moveable storage unit holding all the stuff I couldn't fit in the shed. After covering an entire 100 miles between MOTs I decided to sell it. It sat around for quite a while with people offering me £200 quite regularly. I decided a few weeks ago that for the minimal amount it costs to insure I might as well keep it However the 1.6 75hp engine fitted has very much come to the end of its life and doesn't really have any guts anymore. I had a look around at what engines have been fitted to these. Plenty of TDI, 1.8T and VR6 conversions have been done but none of those really grabbed me.

    While looking around at engines I spotted a couple of build threads fitting the VW V5 engine into older cars. I had a look on YouTube and loved the noise these make. Ok, they're not quite as powerful as the VR6 but to be honest anything is going to be better than the wheezy 1.6 that's currently adorning the engine bay. I started scouring eBay and quickly came across a complete V5 conversion from a Mk4 Golf. It wasn't far away and it was cheap I spoke to the seller who confirmed he was happy to keep hold of it until I could get a spare day to collect it.

    I've done some research and can see the engine mount on the drivers side is different to what's in the van (there isn't one in the van basically!) so I've spoken to a friend who builds funny cars for a living and he's agreed that if I slot the engine in on the other mounts and trailer the van to him he'll fabricate one for me After that all I need to do is figure out the wiring differences and voila! Sounds easy haha!

    I'll leave you all with some pictures of the van looking rather sorry for itself. The bodywork is poor (at best!) but it's actually really solid underneath. It'll get tarted up a little so it's presentable but nothing major.













    Hopefully this is of interest to people so I'll keep it updated as I move on with the various tasks ahead

    Cheers,

    Sammo

  2. #2
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    The van was relegated to the road a while ago and hasn't moved for at least six months. I took the battery off and charged it the other day and then popped it back on the van this morning. It fired straight up as though it's something it did every day (it may of smoked out the entire road with oil smoke when it did this!).

    I took a couple of pictures to send to my mate so he can see the current engine mounts and he already has pictures of the mounts on the engine itself so he has an idea of what he's got to do.






  3. #3
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    Oh and so we all know what's going in. This is the donor engine


  4. #4
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    A few months back I provided the van with a little Christmas present. A new steering wheel to replace the awful original. I'm not sure if I'll keep this one permanently but I'll see how it goes.



    It's quite handy doing a van project in that it can be used to collect everything that's needed before starting the project properly. Once all the big, heavy stuff that won't fit in my 5 series has been rounded up then I can get going properly

  5. #5
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    I was bored this morning so I decided to change the steering wheel over on the van. The original wheel is disgusting and really badly worn, plus the airbag doesn't work and has been bypassed with resistors for some time. I picked up an unbranded steering boss a little while ago so I figured I might as well get on with it. Some progress is better than no progress.

    One steering wheel boss. Seems pretty well made.





    One steering wheel.



    First things first was to get the airbag off. Battery disconnected and instructions given to my four year old who was sat next to me to "get Nanny if there's a loud bang and Daddy looks hurt!"





    Once that was off I slid the boss onto the spline but it wouldn't push all the way home. It would seem that the cheap non branded boss hasn't had enough machines out of the back to allow it to slide all the way on. Looks like I'm going to have to find an engineer who can take a little off the back for me!

    Anyway, I figured I might as well carry on and at least get it mocked up today so it will just be a straight bolt on job once the boss is sorted.





    Once that was on I reconnected the battery and went to try the horn and....... Nothing! I wired it up arse about face. So off it all came again, swapped the wiring around and bolted it back on.

    Voila!

    I don't think it looks too bad. Considering it's all cheap stuff it looks 1000 times better than the original. Annoyingly, where the boss won't slide far enough on the auto cancel won't work on the indicators. I'll get this sorted soon enough

  6. #6
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    Finally some of the parts I ordered have arrived.

    I have so far received a full set of Powerflex bushes for the front wishbones and front engine mount, two new lower balljoints (I'll most likely destroy the old ones trying to get them out!), 1 new front wheel bearing (I replaced the other one a couple of years ago), a set of Mk3 Golf GTI clocks and a Golf VR6 gearbox.

    I'm picking up the engine this Saturday and then that's all the big stuff that requires the use of the van. Which means as soon as it stops curse word it down I can rip the engine out and start lining the V5 up to get the chassis mount made.

    Watch this space!

    (Sorry for the lack of pictures)

  7. #7
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    Aug 2008
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    Today was kind of a productive day. My Daughter and I drove down to Southampton and collected the engine (and gearbox, engine loom, car loom, ECU, key, throttle pedal and all engine mounts!). I couldn't believe it when the chap (Martyn) showed me all the stuff that was included! It's definitely going to make this easier having all of that.

    I even took a a couple of pictures.

    Plodding along the M3.



    Using Martyns' very handy forklift to load the engine into the van



    Finally loaded up and ready for the drive home. Rear engined Caddy anyone?


  8. #8
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    Today I managed to take a (tiny) step forward

    My Daughter went out with my Mum and Sister so I wandered out to the van to swap the instrument cluster to the Mk3 GTI ones I recently bought on eBay.

    Started off with this.



    Buzzed the wheel off and then removed the plastic surround.





    I was surprised how easily these come out. Two phillips screws, tilt the cluster forward and unplug it and out it comes





    Refitting the new one was reverse of removal (I could of worked for Haynes ??)







    Not a massive step, but a step nonetheless.

  9. #9
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    Oh and I've decided I don't like that steering wheel. I can't put my finger on the exact reason but it just isn't nice to drive with. I'm gonna order something different soon which hopefully will be a little nicer.

  10. #10
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    Yesterday I drove to Kent and collected a VR6 flywheel (and the guy chucked in a brand new clutch!), starter motor and very good condition front seats

    This morning I decided to swap the seats over seeing as I didn't really have anywhere to store them.

    These were the originals. Not particularly comfy or supportive and when I bought the van they had enough hair embedded into them to make yourself a couple of fur coats!



    They took at least 2 minutes to extract! Look at the build up of van crap underneath! I didn't have access to a vacuum but the seats will be coming back out again anyway so I can clean it all up.





    It was then a bit of a pain to get the new ones in. They're from a Mk3 Golf VR6 so they're wider and taller although they appear to be lighter than the ropey originals! I had to swap the tilt handles from the old seats to the new ones so the seats could fit. I think they look pretty good though and they're very comfy


  11. #11
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    Over the last few days I've been clearing the driveway of all the crap that's been blocking it ready to at least get the V5 engine out of the van and onto a stand. Today was to be that day



    However, that's as far as I got. It turns out that the 18 months of sitting around has destroyed the seal in the hydraulic ram for the hoist! I've already ordered a replacement ram so as long as the weather is ok next weekend I can get back on it!

    Proper anticlimax aye!!

  12. #12
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    A little update for today.

    My new hoist ram arrived during the week I was working yesterday so didn't get a chance to do anything but today I braved the rather cold temperature and headed outside to see what I could get done.

    I started off with changing the ram on the engine hoist. I was really impressed that the new one came filled with oil and already bled. All I had to do was bolt it on





    Once that was done I got straight on with lifting the engine out of the back of the van. I think I heard the van breath a sigh of relief as the weight lifted off its floor (rofl)







    It got plonked straight on my engine dolly and I set to work removing the V5 gearbox, clutch and DMF. I was having a good look around to see what else isn't going to be needed as well. I can lose the A/C compressor, secondary air pump and I reckon I can knock up a plate to block off the EGR as well







    At this point (probably due to it being rather cold!) I forgot to really take any more pictures ;-| I did remember to take one of the VR6 flywheel once it was fitted. I had a slight panic when fitting it when the bolt holes didn't line up! A quick Google later and some rotating of the flywheel and voila, the bolt holes lined up



    My intention was to get the VR6 clutch and 'box bolted on today but annoyingly the V5 clutch bolts are too short so I'm going to have to get hold of some VR6 ones instead.

    That's about it for today. I'd gotten to the point where I couldn't retain any warmth so came back into the house. Next weekend will be bolting the gearbox on and then spinning the van around to get the old engine out of it and start lining this one up

  13. #13
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    I had a half day off work today

    Unfortunately with no garage the Caddy and engine are currently looking like this ??


  14. #14
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    This morning I got a spare hour to do a bit of tinkering I managed to get the engine onto the stand (all by myself!)so I can strip off the bits that aren't required and turned the van around ready to remove the old knackered engine



    I figured as the van was now facing the right way I'd start taking the front end off. Unfortunately the skies had other ideas and within minutes of me opening the tool box the heavens opened and that was the end of that!





    Hopefully I'll get some more time during the week

  15. #15
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    When I got home from work it was still light! I figured I'd do a bit more to the van By the time I'd gotten changed and dragged my toolbox outside it was dark B-| Not one to be discouraged by not being able to see anything I cracked on with getting the front end off.







    I think the next time I'll get a chance to work on it will be Saturday (weather permitting!)

  16. #16
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    Managed to get a bit more done today

    Got the downpipe off and the driveshafts undone a lot quicker than I thought I would and before I knew it the engine was ready to come out!





    And it's out







    The van is looking a bit high now!





    Once the engine was out I decided to take off the knackered wing. I bought a replacement two years ago and never bothered fitting it. Now I've got to fit it







    Next step will be getting it up on stands to get the exhaust off and get the Mk4 shifter fitted.

  17. #17
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    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.

    Last edited by Sammo; 03-04-2018 at 07:12 PM.

  18. #18
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    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

  19. #19
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    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!)

  20. #20
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    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!

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