Giving a 405 Sport Wagon another chance

6 minute(s) of a 111 minute read

Finally this engine is installed and I'm hoping it will be there for a long time. What have I gone trough to have this engine and finally see it inside of that engine bay was really unbelievable,I don't drink at all but I did open one beer and took few minutes just looking at it and some part of me still can't believe it's actually inside and about to run.

Engine did bolt in right in place but shift fork and shift bracket needs to change with 5 speed ones if 6 speed gear box is used. Also phase II 405 clutch cable needs too be used as GTI6 clutch is pull style. Non of these things were noted on any forums that I've visited. Once I'm done and it's running and driving I'll make a full write up on GTI6 to 405 swap so next guy does not have my headaches.

I also order tachometer adapter from Spoox motorsport.

Pictures below is shift bracket that needs to be swapped over and yes shift linkages are the same and work just fine. Also if you have 91 vehicle you will need 89 style shifter knob as reverse is pull type by first gear.

Left shift bracket is for 5 speed and one on the right is 6 speed.

Left shift bracket is for 5 speed (not powder coated one) and other on is 6 speed. Both of these brackets are needed out of 5 speed to use 6 speed gear box in 405.

10-20-2015

I've got all OEM parts from UK already so no need for electric vacuum pump. Yes I received tachometer adapter from Spoox Motorsport today. It's converting digital signal to analog to get 205,309 and 405 tachometer working with 306 GTI6 engine.

10-23-2015

I got my personal license plate :-)

I also ordered GTI 6 battery-ECU box for cleaner look.

This GTI 6 intake manifold is work of art. It has velocity stacks built in,truly amazing.

I'm thinking to get another one for my MI16.

11-4-2015

Local Hose&Fittings shop made me new P/S pressure hose and I needed about 4 feet of 16mm return hose. I bolted it all in place today and it fits great.

I had to modify A/C accumulator and move few hoses in different locations so everything can fit properly. Accumuator got flipped about 180* and now it's pointed up. One of the mounting holes was there already so I just drilled one more 6mm hole for better mounting. I left bottom mounting ear as it has two spot welds on it which makes it very strog and engine vibrations won't brake it.

Before I get it all back together I'll paint accumuator black.

11-5-2015

I had to cut out lip on fraim rail about 10mm as 6th gear housing was lightly touching it.

I also installed battery box,cables and battery.

11-16-2015

A/C lines are routed correctly to fit this engine and I painted accumulator semi gloss black. I also made engine harness to body harness bracket-plate and it will be powder coated gloss black after engine brake in. I got 306 body to engine harness pig tails to mate it to 405 body harness.

On Saturday I installed vacuum pump for brake assist,connected fuel lines,installed and charged battery, and started on wiring fun.

I called it quits at 1:30am after having insufficient information on second engine harness connector. It seems like no one in UK is using it,however I need it as I have A/C,oil level and oil temp gauges.

UK guys don't have any use of A/C,check engine light,factory oil gauges or OBD II. So pretty much that's what kept me from having it running and moving on it's own power.