NEWBIE NEED HELP PLEASE

Hi there ive got myself a mk1 gti 1.6 or i thought it was, seems that it has a 1.6 carb engine in it has anyone got a clue where to start converting it to a 2.0 16v from a 1992 mk2 ??

any help would be great

welcome to the site.
should find what you need here http://www.vwgolfmk1.o…ontent&pa=showpage&pid=39


get some pics up

ash

thanks for your help but still not much wizer am i rite in thinking because i dont have an injected engine to start with that i need alot more to do the conversion to the 2.0 16v and any idea about the wiring needed ? thanks

Well for a start, is your car a GTI fitted with a carb engine, and/or does it have a lot of the fuelling components removed? For example does the car already have all the differences such as fuel pump, accumulator, larger diameter lines, fuel pump relay, etc. It will make a difference in terms of the amount of work required, and additional parts, you'd need.

Secondly how much of the GTI wiring remains? If the wires and plugs for WUR, AAV, CSV and TTS are still there, then you're 4/5th the way there in terms of wiring up the 2.0 16V

Thirdly, the Mk2 Golf never (except in USA….) came with a 2.0 16V, so that too will be an engine conversion. What did the Mk2 start out as, in life? How was it converted, in other words what fuel injection system was used? K-Jet? KE-Jet? Electronic FI (for example from an ABF engined Mk3 Golf, which is reasonably popular)? Some aftermarket EFI? Properly done with all the components present, or stuff missing etc? Carbs?

No guide will exist to cover your exact situation because you're starting from non-stock cars to start with. So you need to take a close look at the items your car, and the donor car, already has. Do you have full access to the donor car to remove parts, or is the deal involving only the engine? etc. Too many unknowns to give solid detail on yet.

OMG sounds like i have biten of more than i can chew here i'm buying the engine with ecu and ecu loom which is a 16v from a 92 mk2 my mistake in thinkin it was a 2.0 it may be a 1.8 (most likely) havent got a clue about the wiring left ?? the car is down as 1.6 gti on the v5 and at some point the engine has been out and the lot respayed and then this 1.6 carb engine put in dont know why, could it be possible that its not a gti ?? and if so can the conversion still be done ?

thanks for your help

none of the work has be done to the fuel line will i need a new tank or can i just put on bigger lines and a bosh fuel pump of some kind ??

You've not bitten off more than you chew - don't worry! Its just that some people might gloss over things, rather than giving the full details on what needs to be done etc. Needless to say, with an engine conversion there's lots and lots of little things which all need taking care of. If you're not confident to do this - don't do it! While you can pose questions on the internet and everyone will try as best they can, at the end of the day, you're the one who'll be screwing it together, buying the bits and driving the car, etc and if you're not at least reasonably confident in your ability, then it will fray your nerves a little. Everyone has their level of skill which they're comfortable in?

Wiring - you're looking for 4x "RS junior timer" plugs, I think the CSV is blue, the WUR and AAV are brown, and I can't remember the colour of the TTS one. Maybe someone can post pics or a search would reveal them. Its quite possible they've been bundled up, or one has been chopped to feed an electrical connection on the carb (eg fuel cut off valve).

Fuelling - you're looking for the hole/pipe fitting in the right side of the tank (low down at the side); a fuel pump and the fittings to attach its cradle to the underside of the car. Its fitted just to the right of the fuel tank. Then a bit further back, is the accumulator, you'll need its bracket and fittings into the chassis too. The fuel lines are thicker than carb ones, I think its 5/16 instead of 1/4", and they'll run along the underside of the car on the right hand side, then enter the engine bay near the wishbone support, then cross right-left in the engine bay just above the steering rack, and behind the column (UJ), ending in screw-on high pressure fittings. Its possible that these have been chopped, to fit the carb, or simply (fingers x) that flexible lines have simply been fitted over the top and screwed on with a hose clamp or something.

The Mk2 is most likely a 1.8 16V, if you have access to the whole car then there's a few little modules to remove, in addition to the main bits, to beware of. http://www.fastgolf.or…ontent&pa=showpage&pid=30 contains a list of parts which is pretty extensive, of what needs removing from a donor car.

thanks so much for your help you really know your stuff, i'll get a look for the wiring connections and have a look at the fuel lines hopefully when it stops raining,

should be easier as ive got the head of the engine and the gearbox out which ive had refurbed

will the gear box fit the new engine ?? and do i use the flywheel/clutch from the mk1 or mk2 ?

thanks again

Your existing gearbox will fit the new engine, though you need to match the friction disc (part of the clutch) to the gearbox you intend to use. There's a few disadvantages and no real advantage with the 16V box, so if you have the existing 1600 GTI box, I'd be tempted to reuse this. If you have a different gearbox, then it would depend which bunch of ratios you have, whether its worth swapping for another, or makeing the necessary alterations to use the 16V box (different driveshafts, basically) or sourcing and fitting a different box again.

There's a lot of different options, everyone has slightly different opinions on what's best and what's not so good, etc. So there's no right and wrong, just opinions/guidance/experience of others, to draw on.

i thought the gearboxwould be ok but wanted to confim thanks

got some pics of the wiring in the engine bay and a pic of the fuel lines which come in on the left is this not where they need to be now ? the look like they have been changed and run the lenght of the car in red plastic pipe dont know what size though look about 10mm ??

dont know how to put pic up ?