some advice please :)

I have been offered a mk2 gti complete car with a 2.0 8v engine that i want to put in my cabby which has a 1.6 carb at the moment
and i would like to know wot i would need to do to get it running in my cabby
i will have the complete car as a donor and want to use the engine and brakes but not sure wot i will need for the fueling and wiring in the engine bay
cheers Aaron

In doing something similar on mine at the moment.

For fuel. You will need the electric gti spec pump which lives under the car, a gti or polo g40 lift pump which is the thing that sits in the tank.

The engine itself should bolt in using the same brackets as far as I know.

The wiring will need some modifications but if your unsure just contact rubjonny and he may be able to do it for you for a small charge. He did mine and its as good as can be.

Do you have much mechanical experience?

cheers denisotto
ok i'll source both pumps so thats sorted and yeah it should go straight on my mounts
i have lots of mechanical experience had lots of vw's and always do my own work so shouldnt be a problem just wanted to make sure wot i needed to get it done really
i will contact rubjonny for more info on wiring cheers mate

well i have managed to fit my new engine in and have wired it all up including MFA and dials with help from rubjonny cheers mate
all i need to do now is fit the fuel pumps and wire them up and then hope it starts lol
i have 1 problem i am not sure wot to do with and wondered if anyone on here can help me
this is the problem



wot can i do with this so my bonnet will shut wen i put it bk on lol

cheers spides

Cut down the airbox so its much lower.

Or use a Mk1 airbox, with a slot cut in the bottom of it (not sure if thats a Mk1 or mk2 airbox you have there).

its a mk2 airbox on it at the moment didnt know if a mk1 airbox was different tbh will have a look for 1 want to get it running this week
cheers

Can't you put a Mk1 inlet manifold on it and then use the Mk1 air box as a normal Mk1 GTI ?

just cut the bottom out of it, since that is what you have. no need to spend any more money! this is what my mk2 16v airbox looked like when i was done making it fit:

cheers mate will cut mine down so it fits
rite i have got all the engine back together now and tried to get it started today but it wont fire
i have connected all the wires i could match up at the fusebox and dont think there are anymore to do as far as i can see
it does sound like it trys to fire up every so often but then nothing i have spark at the plugs so its not that but not sure wot else to check at the moment
will be bk trying to get it running tomoz jus wondered if anybody had any ideas on wot to look at first any help would be much appreciated

Ignition timing, and fuelling

Ignition timing - its possible to check the static timing, so you could put it somewhere more or less right.

Fuelling is harder to set until the engine is running and warmed up, but using cold start fluid can sometiems coax it into life, if the fuelling's a bit out.

the engine was running the day before in the mk2 fine and i havent touched the timing at all the only changes are the fuel pump which i will check tomoz so is the only thing that could be the problem as far as i can work out unless i've missed something in the wiring somewhere

If its almost starting (coughing during starting, etc) then it suggests somethng like timing or ignition. If you'd missed a critical wire connection, it would just turn and turn with no attempt to start at all.

Does it change engine note or do anything different if you alter the throttle during trying to start?

If the wiring connection is non-critical….then it would start.

What fuel pump are you using? Connected the 5th injector too, is this firing properly? Aux air valve, warm up regulator and thermo time switch?

well it does try to fire then nothing so the wiring must be correct for the engine and i did double check all wiring before attempting to turn it over so hopefully i can rule that out as you say
i dont think it makes a diff wen i alter the throttle wen i try to start it but will listen more to it today
I'm using a mk1 pump at the moment but think i may have a problem with that as it does make alot of noise but will be redoing the fuel pump connections today so hope to sort that out
as i didnt disconnect anything on the injection system i'm assuming the 5th injector is still connected as was and will be checking the other points today so hopefully i can find the problem and have her running

well it does try to fire then nothing so the wiring must be correct for the engine and i did double check all wiring before attempting to turn it over so hopefully i can rule that out as you say
i dont think it makes a diff wen i alter the throttle wen i try to start it but will listen more to it today
I'm using a mk1 pump at the moment but think i may have a problem with that as it does make alot of noise but will be redoing the fuel pump connections today so hope to sort that out
as i didnt disconnect anything on the injection system i'm assuming the 5th injector is still connected as was and will be checking the other points today so hopefully i can find the problem and have her running

Not my strong point engines really, but I had similar issues on my car with a really whinney pump.
So on my car there is a 5 pin fuel pump relay, some are 4 you can use a horn relay, apparently.
The fith pin takes a supply from the coil, this is supposed to help, with rev limiting.

Also another problem was a mucked up fuel filter & it was filthy.

So did you service the engine before hand?
Could it be an air lock in the fuel line?

Just a few thoughts really.
But like I say engines is not my area at all.
Would cutting the airbox though just let more air in?
I pressume you have to re enclose the area you cut out or otherwise loads of air will just get and weaken the fuel mixture?

No doubt Paul and Johnny will come along and tell me that's nonsense lol.

cheers chortle engines are not mine either really lol but thanks for your reply i have pm'd rubjonny so hopefully he can help

i have also noticed a couple of connections that i think need to go somewhere and again hopefully rubjonny can sort them out for me

i havent cut my airbox yet as trying to get the engine running before doing to much else to it
but i was under the impression you cut the bottom off and leave it like that but i could be wrong lol

Cut airbox will make no difference, the bottleneck on airflow into an engine is the throttle.

Fuel pump wiring and relay - if its making a noise during starting, then that's okay. If its too noisy, then it points to an issue but it shouldn't prevent starting unless its so bad as to limit fuel pressure.

It could be fuel lines needing bleeding if they've beep taken apart and reconnected. To do this, remove the pipe in between the metering head and throttle body, and lift the metering head flap up while cranking the engine over (or at least with fuel pump running). If/when it starts to flow fuel it will probably flood the engine, to clear this continue turning the starter motor but with the throttle fully open.

doesnt matter what you do airbox side, any extra air is metered by the flap in the metering head so no big deal air leaks after the flap are bad though so check al lover carefully for loose nipples, open connections and badly fitted or cracket rubber boots.

you can use a horn relay for testing only, they arnt right for both safty and the fact the terminals arnt big enough to fit the socket properly. but good to rule out faulty pump relay at least.

you shouldnt need to bleed the fuel system as it'll eventually sort itself out, though i guess a bit of stubborn air can be stuck somewhere. certainly wont hurt to do as above though anyway.

could be fuel filter needs repalcing, or the non-return valve in the fuel pump has gone. on my cab it just packed in one morning! i tried everything and eventually had main pump pointing into a bucket and no fuel! pump sounded just fine. i swapped a mk2 k-jet valve over to the mk1 pump and hey presto all was well! i have no idea how a nr valve could fail in that way but i wasnt going to argue