Having widened the search to include the less powerful model with single-point injection, I eventually found a suitable car in Swindon - a 1990 GTi 1.4 16V SPi. It had failed the MOT test on severe corrosion to the sills and floors - I think the side skirts are holding the car together! This car will provide the gearbox, brakes, suspension, steering and wiring loom for the Onyx. The engine ran OK during a short test drive, but a later compression test revealed low compression on cylinders 2 and 3. I suspect the head gasket has failed (a very common problem on K-series engines apparently). If so, it will need replacing, or I may look around for another complete engine, preferably with multi-point injection.
Not bad on the
outside, but completely rotten underneath.
A reasonably clean engine bay. Note the new MEMS ECU behind the battery.
The quick and easy way to remove the radiator, cross-pipe and cooling fan in one piece. I cut through one end of the slam panel with a hacksaw, then removed the two bolts from the middle, allowing it to be bent out of the way. Such finesse.
Ready to
drop.
Out! A bit of blood, lots of sweat, but no tears. Thankfully
(and rather surprisingly), I had no problems with seized or damaged
fasteners.
With all the mechanical bits gone, it's time to strip the
interior. Nearly everything has to be removed, in order to get the
complete wiring loom out.
The front lower seat belt mounting came out like this. What a death trap.
After
removing the loom, I carefully refitted all the interior
components.
Like the front one, the rear subframe came out without a
fight. Most of the dark stains are not from oil leaks - they're the result
of liberal sprayings of WD40 on various fasteners.
The complete
wiring loom. Yes, I did remember to tag EVERY connector.
14 years worth of
grime. I've got some cleaning to do!