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1991 Caravelle 2.0i syncro
09-03-2015, 04:41 PM
Post: #1
1991 Caravelle 2.0i syncro
Hi all, just want to start marking the start of my project. Bought the bus about 2 months ago and had some issues but been going good as a daily drive. Put on about 6000 km since then.

Here are some pics of the current state

[Image: 12c64e0067ad58d69947c648855fe5a4.jpg]

[Image: b5db47f1220b7ca385d00342d8ee0b04.jpg]

Currently fitted with a 2.0l ADY golf engine with a Gotech management system, which will be replaced soon with MP9.

Petrol cable snapped due to previous owner badly fitting the cable and was tight as it being in the wrong place. Fixed that this morning and its much smoother with a new cable running the correct path.

Front wheels has some movement so decided to replace the damp ring, upper control arm bushes and ball joints and lower ball joints. Stuck to everything Febi as I have good experience with it. Feel free to suggest something else

Will hopefully with them this weekend

[Image: 006e8ad07b7889f82c79afe621cf9ca7.jpg]
[Image: eaa0211acd093e83903a345dda7b561e.jpg]

By budget not exactly massive so the whole project will take a while, but the bus should be going in for a colour change in about 6 weeks. Feeling excited

Will keep posted as and if things happen
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09-03-2015, 06:18 PM
Post: #2
RE: 1991 Caravelle 2.0i syncro
Nice looking bus hou have! What colour you going for? I like the two tone it is tough,also like them two tone silver/gray. Enjoy the project Dirkie. Wish mine was going already..
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09-03-2015, 08:37 PM
Post: #3
RE: 1991 Caravelle 2.0i syncro

Nice wheels

1989 2.1 SYNCRO
2011 CB1000R

Stuart said "They say in "Namibia" the only problem with a syncro is when it does get stuck nothing else can get there to tow it out"

SYNCROnized OFF-Roading
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09-04-2015, 08:11 AM (This post was last modified: 09-04-2015 08:12 AM by Dirkie2710.)
Post: #4
1991 Caravelle 2.0i syncro
Hi vic, first instinct was to go for an olive greenish colour. Something like below

[Image: 6bf02b5db0dfc94a33104b91973ec733.jpg]

As I searched I found these syncro photos so might go for somethung like below. Still have to decide
[Image: 5332184032c8b2df1dad48c5bedef960.jpg]
or [Image: 914fc427ade256cc84543d4182ed9810.jpg]

I get many comments about the wheels and I don't like them for some reason. Maybe its just me. When bus is greenish colour I'll get some matte blackish wheels hopefully

[Image: d7a9c1583dacf0e74330f5ba8cf17f08.jpg]

[Image: 8c0027c60d86fc42a2b88e3e84dd32b8.jpg]

[Image: 7f0333bd2710da2ec2c333cd6300c3a9.jpg]
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09-04-2015, 04:58 PM
Post: #5
RE: 1991 Caravelle 2.0i syncro
Like the colour in the last pic!
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09-21-2015, 05:00 PM
Post: #6
1991 Caravelle 2.0i syncro
Ok so its been a quiet past few weeks for the bus as work has picked up significantly.

Previously I replaced the petrol cable it was due to a snap and the bus was new so didn't have my box of spares in the back, so have to do a roadside repair of the existing cable. Luckily the snap was between the long brass pointy bit and the shorter square bit where the cable mounts so I had to saw a gap into the bolt to slip the cable in so I could atleast get home. In this I noticed the bolt was a real piece of crap, which had a flat head screw instead of a hex bolt or allen key and 1 washer which was 3 sizes too big, and would need replacing.

[Image: 4bd66f266ad13c290537d24a590af9c6.jpg]

Searching Vagcat I found what the bolt should look like, and not finding it at any of my usual suppliers, and not liking the bolts they do have, I decided I would attempt to make my own one.

Problem was the bolt I had finaly gave in Friday afternoon leaving work, and I was to leave to Kroonstad on Saturday morning, leaving no time to actually get the part before Sunday when it needs to go in. Got back on Sunday morning, not having any replacement part or an idea of where to start.

Looking through the toolbox I found a nice old plug. Solid brass, not these new folded types, and decided thia would be my new bolts. Some measuring with the vernier and a quick few sketches and I was busy making a bolt. One failed attempt later and I had my bolt. Just a few drills with the Dremel and a tap from the cheap Midas tap set and all was good again.

Got a few washers and a hex bolt and iff I was to install my newly made bolt.

[Image: ac8635e8b0b46b7630bd827ff2ba3b37.jpg]

Not to bad for my first time I think. But also not the best. Also not to keen on the brass idea, but will have to do until I can source a proper replacement.

On the MP9 matter, a colleague sold me an intake with accessories. Not too sure what I actually got as I am not clued up with MP9 systems, but at R500 it was worth the risk even if useless. Can anybody make a call on what it actually is. I've also got a ECU from a Polo to go with this

[Image: 55ef85c2672b1ea5abcd983b60f86a5e.jpg]
[Image: b94f3673901f8d89b9fcad67b74917a1.jpg]
[Image: dbc3bbb8d36a01f82e25e20182518758.jpg]

This is what the current intake etc look like. To me it looks the same, expect different harness.

[Image: 37a47837a1fa7bbdb99ace786ba5c690.jpg]

Advice and guidance is always welcomed

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09-21-2015, 05:08 PM
Post: #7
RE: 1991 Caravelle 2.0i syncro
On the Mp 9, you just bought yourself a set of spares, your bus has everything on it ready for MP 9, you just need a wiring harness, ecu etc, all the rest is good.

I may be a mechanic, but i can't fix stupid
Bad planning on your part does not make your issue an crisis to me
Bad workmanship by other garages does not entiltle you to better rates at me
Syncro, syncro , syncro and more syncro, this is the syncro way of life
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09-21-2015, 05:10 PM
Post: #8
RE: 1991 Caravelle 2.0i syncro
Thanks Stuart
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