help

Hi, i've fitted a 16v kr engine to my mk 1 cabby 1990 , could any one help me with what throttle cable i require?  

I used the old one, but adapted it.

Thanks mate, i'll try that , do i have to upgrade the fuel pump/ system?

It depends what kind of cabby it was. Carb: yes. GTI: no.

when we bought the golf it had a kr engine 16v  already in , running on bike carbs , so we sold that to buy a kr 16v standard injection engine, trying to put back to normal, just the throttle cable and fuel pump a prob

There's no set way to get the fuelling working on a car with bike carbs, obviously its been modified, and probably poorly because someone's already made the poor decision of choosing bike carbs and junking a perfectly functioning fuel injection system!

The original question still remains though: did your car originally start out as a carburettor powered one (GL, GLS, or Clipper) or a fuel injected one (GTI or GLI)? If it were a GTI its possible the previous bike carb conversion retained many of the GTI fuel system components, which are the ones you'll ideally want to have there.

Also, what year is the car? Later cabbys have a different fuel tank and other fuel system components eg lift pump and separate reservoir.

If its carb, you'll probably want to upgrade the fuel lines too (GTI used larger diameter stuff), as well as sort out an electric fuel pump and accumulator, which can deliver 5 bar. The wider fuel lines help reduce the pressure drop from pump to engine which can be an issue.

the car is a 1990 1,8 clipper we think , your bang on about the bike carb conversion , as it was poor, thats why were trying to put it back to norm, as norm as with a mk 2 1.8 16v kr

1990 will have a newer style tank (bolt in, not the previous secured-by-straps one).

You'll need an in-tank lift pump from a later GTI cabby or Mk2 Scirocco; external reservior, the 2nd fuel pump, accumulator, all the fuel pipework connecting these components, and the fuel piping from accumulator to engine bay. Even then, you'll need to modify this fuel pipe to bend it to the other side of the engine bay, unless you also have a Scirocco 16V inlet manifold (so the metering head remains on the same side as a standard GTI). Some of the fuel pipework, accumulator and high pressure fuel pump will be the same as hatchback GTIs. You'll also need the brackets which hold these items to the body underneath, and also check you have the securing studs for these, if not then you'll need to somehow add them (welding….near fuel tank….?)

Additionally, tho not 100% sure because you already have a later cabby, you'll need a fuel pump relay and the relevant wires to the pump. The fuseboxes are internally wired the same so you should be able to simply plug in the relay and make a couple of additional connections at the rear for it to work ok. The wiring diagrams will guide you here, for the 2 connections you make. GTIs will also have a T piece electrical connection and power wires to the aux air valve and warm up regulator, although for a 16V you might run ISV instead of aux air valve.

for throttle cable i used a mk2 gti one which worked well. it needed a bit of silicone lube as the new gemo cables are a bit dry from new.

you can also get the lift pump & reservoir from any MK3 Polo (G40 shape) if thats any help. then its a case of getting a fuel accumulator under there (ideally use late cab/rocco as its smaller than early mk1 and mk2 golf one) plus a std k-jet mk1/cab/rocco main pump + lines to engine bay.

if you have money then the crazyquiff 16v conversion line kit is a direct fit for you and good quality. you'll also need a mk1/cab/rocco fuel filter, bracket and the 2 lines from it. these will bolt right onto the mk2 16v metering head.

if you want to use the full mk2 16v isv system, the best airbox to get is the pre-90 mk2 16v as it will fit next to the engine on driver side, post-90 is too wide. mk1 airbox fits but it doesnt have the right connections on it for the breather and the over-run cutoff valve, so that needs a bit of tweaking. if you want to use the aav then mk1 or mk2 airbox is fine. either way you need a 90spec airbox boot as the pre-90 is way taller and hits the bonnet. i actually managed to stretch a mk1 gti boot onto the 16v air flap assembly, but its a bit of a struggle and not ideal as it might split in the long run. did me fine for 2 year tho.

the fuel pump relay pin is E/14, and it needs to have a spade connection hanging off it for the WUR (and aav if fitted) you could also use the earlier mk1 T junction thingy if you can get one instead of an extra spade wire though.

you can buy the pins from polevolt.co.uk or you could just get another CE1 fusebox plug and chop the large pin out of it. then as above fit a fuel pump relay, if you do a proper mk2 16v wiring loom then you can use the 67/80 or 167 relay from mk2 digi, 16v or mk3 petrol. if you dont wire it up like oem 16v then use a mk2 k-jet relay without a rev limiter, GSF will sell you one.

basically the difference is 16v has a fuel pump relay earth trigger wire to D/13, if you miss off this wire then you need a k-jet relay which uses a rev counter signal to trigger it instead.

any one out there got any of these parts?