2.0 8v into mk1

hi all, im putting a bora 2.0 8v engine into a mk1 engine code is AQY
the main info i need is wiring diagrams and any other info to help with it.
the loom has been carefully removed so i have nearly all of it, i want to use the mk1  clocks so i will have the ecu imobiliser removed.
what sensors do i need to keep and what can i remove? id like to keep the diagnosic port as well if i can.
i noticed that the injectors have tubes on them that where connected to a air pump on the front of the engine do i remove them and fit injectors that dont have the pipe?
then also remove the air pump.
i take it that fuel pump relay is driven from the ecu so should be simple to sort out.
also what pump do i use has it has a k-jet type on it at the min, would that be to much pressure for the newer type injectors
what mounts are needed for the gearbox
and do i need to fit a 16v cambelt tensioner like you do for a 20v turbo engine.

thank and look forward to some replies. 

most of the wiring and sensor information you need is here: http://www.clubgti.com/showthread.php?267196

injector tubes not sure on that one? if you can find the spec of the injectors and get more that are the same then you could do as you describe. or maybe just block off the pipes on injectors for an easy life. pics?

kjet pump is more than good enough so keep it if its in good nick. fuel lines will need bending over to driver side and/or shortenign, but if they look bad underneath id bin em off along with accumulator and all associated pipes, fit an m12x1.5 -> 7/8mm barbed banjo adaptor into the pump then fit new rubber or plastic fuel lines. the mk4 pipes may fit well?

gearbox if its 02j cable shifter its as per mk1 20v, custom mounts then hydro clutch conversion, or seat abf/tdi cable conversion kit, plus mk1 cab/rocco 100mm driveshafts. if its something else let us know what it is and we can advise. But since the 2.0 8v isnt that amazing power wise you could just swap your old gearbox over it'll be fine. put a new mk1 gti clutch on it and fit your odl flywheel, job done.

cambelt tensioner I'm not 100% on those, I assume its basically the same as a 2.0 8v mk3 lump in which case its fine to keep the stock setup, or you may be able to swap mk3 parts over to convert? pics?

i found this info,  look at page 9 & 16 for the injector pipes for injectors
http://www.volkspage.net/technik/ssp/ssp/SSP_233_GB1.PDF
also do i need the secondery air pump as per page 13?
i take it i dont need n80 n112 j299 v101 that is on page19.
thanks again
stu

SAI is always binned on 20v swaps, you dont need it once cat is binned sop all the associated gubbins is also binned. carbon canister is also filed under B for bin.

the air shrouding that one is your call, unless its a pain to keep it I would just leave it as is, save you a bit of effort and apparently it helps

What alternator belt would you use on this engine seeing as the aircon and power steering pumps have been removed ?




  

once built up you would run some string round to see what the length is, then do a little shopping

Cheers mate

another question john will the usual 8v 4 branch manifold fit this engine ok i assume the head is very similar to early 8v . cheers

I'd be pretty sure its a tall block liekthe mk3 lumps, if so most will probably hit the rack/uj. tbh for an 2.0 8v you dont need anythign fancy just get a standard 6 bolt flange mk1/cab/rocco injection 4-2-1 manifgold and downpipe. The oem stuff flows very well. if you must fiddle you could port match em

its no going to be messed with yet just get it in and running, obv the bora manifold not be any use so was going to keep an eye out for one (4branch) but if a standard is fine that will do.
fuel pump realy wich one do i use mk1 or bora (149ish)?
 cheers

the mk4 manifolds are offset closer to mk1 than mk23 so could be useful, though you would have to make a custom downpipe even if it did end up right for a mk1 shell.

Generally you would use a 67/80/167 relay in slot 2 if you wire it up as per my guide, but keep the bora relay it may actually work. whats the relay number on it and does it actually fit your fusebox?

if it does fit post up the relay pin numbers and matchign socket position numbers and I'll look it up. some have used mk4 relays in a CE2 fusebox but I'm not sure if the CE1 fusebox has the right sockets

surprisingly it does fit the box it has about 8 pins im sure its no 149 but im not in front of it now so will check later, i read somewhere that it needs a pulse from ecu that the earlier relays dont work with,  but i cant see why that would be.

yeah these are an earth triggered relay same as the 67/80/167. the reason the guy i mention used the mk4 fuel relay is he found his ecu earth trigger was pulsed rather than straight earth trigger. but ive not heard of anyone else having this problem!

ok so il pu in one of 67/80'167 as it may be easier than trying to get the 149 109 or watever it is working cos dont they have crash and door sensors or something?

if its the right relay they will work the same way the 67/80/167 relay do, just wanted to double check which one and what terminals line up to where on the fusebox

they have extra crash signal and door open pins etc but will work with just the ecu trigger

sound, im just reading the thread on the wiring at the min so hopfully i can get it all in and done soon, iv striped all the bora loom down to just the ones i need now so just making sure iv got all i need to put the mk1 back together.

on a seperate note do you have a plug for digifiz??

nope sorry!

well been busy with other stuff but managed to get the wire/pin outs for the plugs they are..
orange 10 pin plug
1grey/ white             diag port k
2empty               
3black/ green           ?
4white                       ?
5 empty
6blue/white              speed sig?
7 green                     air con
8 blue/red                air con
9green/brown          rpm??
10 black/blue            ?

can you confim the ones iv id'd are correct and also the blanks 3,4,10 what are they

next is brown 6 pin
1black/purple            ign live
2 purple/white           fuel pump but what
3red/black                  starter, i asume i use mk1 wire
4red/green                perm live
5blue/yel                   fuel pump but what
yel/black                   again fuelpump, what

also white plug 10 pin
1white/red             ?
2 black                  } both 2&3 link to the orange canbus
3 white                  }wires
4 blank
5brown red           ?
6brown/white        ?
7 blank
8 blank
9 blank
10 blank