16v conversion....progress

Well the last week has been slow progress, what with going away on holiday for a long weekend and general duties that need doing at home, but a little progress has been made  

First job was to remove the engine and gearbox from the mk1, then set about with the degreaser and clean off 26 years of grime in the engine bay………….







Next I removed the gearbox and went down the local jet wash and gave it a good steam cleaning, leaving just the old engine sat on the floor (will strip and rebuild at a later date), she served me well, but was starting to feel her age  :? …..







Here's a little photo of the 16v engine with a bit of black paint thrown on her to tidy it  :mrgreen:



The next issue was to remove the clutch/flywheel assembly from my old DX engine, as this is needed to marry up the original gearbox, firsty off remove 9 bolts holding the flywheel, then you need 17mm socket to remove the pressure plate from the end of the crank, I also needed a help from a friend in holding the engine steady while I cracked these bolts off  :?







I'll add more photos tomorrow………….  :mrgreen:  :mrgreen:

With the pressure plate/flywheel removed from the old DX engine, it was time to remove the flywheel from the 16v engine, as you can see, I've already undone the 6 bolts with a 17mm socket……..



And away with the Corrado's flywheel  :wink: ……………




This then reveals a cover plate……



Using a 10mm socket, undo the cover plate from the 16v………



Also removed the plate from my old Dx engine, to use on the 16v engine….



Removed from the DX engine…….





Quite dirty too  :? …………




After a bit of a scrub up   …………….




The DX plate fitted onto the 16v engine……….



Fit the pressure plate from the DX engine on the crankshaft of the 16v…….



Fit the ring washer to the pressure plate……….



Then the bolts, with a touch of loctite…………




Torque the bolts to 60lbs/ft…………..



Fit the plate and its clip, very easy to do………….





Fit the flywheel with the friction plate, make sure you line up the dowels on the flywheel………

Another little issue with the Corrado's 16v engine is it doesn't have the same O/S engine mounting that is used on the DX engine, as you can see in photo……….



Not a problem   , having removed the mounting from the old DX engine and also fitted a new bush, it was merely a case of clean the threads up on the 16v engine and mount it in the same place…..








To be contiinued…………  :mrgreen:  :mrgreen:

GAMMYGOLFGTI said

With the pressure plate/flywheel removed from the old DX engine, it was time to remove the flywheel from the 16v engine, as you can see, I've already undone the 6 bolts with a 17mm socket……..

Looks like you're using a 9A engine (these use 02A trans, hence the different style flywheel)?

Nice one warren some good work going on there.
keep up the good work.

ye sir gammy,nice one,will get you a hot chocolate at the clubhouse next time were there  :wink:
Bert

Its looking good Gammy ,i mean Sir Gammy

 

looks sweeat gammy  :y:

Nice one. 4 branch too  8)

dont throw away the flywheel i need a 02a flywheel

bens_cab said

dont throw away the flywheel i need a 02a flywheel

Your welcome to the flywheel Ben  :wink:

You noticed the 4-2-1 manifold Raj  :wink:  :mrgreen:

Bert/Corky, I would guess it wont be ready for the next Midlands meet, it's easy enough to do in time…….. but not at the pace I'm working at  :twisted:

One thing I was interested in looking to know, was if it was possible to remove the blank in the 16v engine (where the DX engines distributor fits) and fit the original DX dizzy (Just something I would have liked to do, not saying it would be benificial to the project) see photo below………..




However……having eyed up the the height of a DX engines distributor, it would clash with the inlet manifold, so that wont be happening.  I will get round to pulling the distributor off the 16v and see if the hall sender from the DX's dizzy will fit inside (again, not anything beneficial, but my personal choice to see if I can stay with the original ICU )




Now, I'm not going to be thraping the Mk1 around Silverstone, just your usual high speed motorway driving and a bit of devil driving occasionally  :mrgreen: . So my next alteration, unless someone says it's not possible, is to take off the efficient water cooled oil cooler on the 16v…….





And put the original ram air cooled oil cooler from my DX engine, onto the 16v……




These alterations may not be right, but I would like to do the basic approach to the conversion where possible…..not a money issue, just preference, time and trials will tell what turns out good/bad     :doh:  :pray:

To be continued…………….

 :wink:

Notwithstanding clearance with the inlet manifold, you'd probably need to fit an intermediate shaft with a cog to drive the dizzy if you wanted to retail the 8V position.

9A dizzy is 4 shutter so it doesn't need to be taken to bits and the hall sender swapped etc. It doesn't have any vac/mech advance though, so you need to do this typically with a 16V ECU. The plug for a 9A hall sender was the same as the one for an 8V dizzy. There's 2 variations of plug in 8V though, over the years. So yours might not fit.

I'd personally retain the water/oil cooler and ditch the air/oil cooler. Well I say personally, I used the water/oil and a thermostatically controlled sandwich plate with an aftermarket air/oil cooler, ditching the rather troublesome Mk1 item.

Cheers for the info Paul, haven't totally decided whether to change the oil cooler , will make my mind up this weekend  :y:  :y:

Right back to it…….

Next step, was to fit a new water pump, very cheap and the same pump as fitted to Mk1 Golf, I also borrowed the bolts from the old DX engine, as the 16v water pump bolts also accomadated  the power steering pump and were too long






Sitting pretty, but missing something??……….



Yep, the pulley is missing - do not use the pulley from the 16v, as it is a twin pulley which free wheels  8O ……..
Go back to the old DX engine and get the pulley off the water pump…..


and there is the old pulley on the water pump………



You didn't think I'd leave it that rusty, did you? removed it for painting  :wink:

Gotta love 16v's!

coming along nicely gammy  :clap:

kuc said

coming along nicely gammy  :clap:

long time kuc, where you been :dontknow:

Hi ans4er, busy with family and work dont know where the time goes. Have been catching up with things on here, will try and pop to next meeting hopefully. :y:

Hi Kuc   ,   as Ansar said, haven't seen you in a while…dont become a stranger, there's always a seat spare at the clubhouse :y:

Haven't got any photos to put up at the moment, but the engine is in, the driveshafts are bolted up, the Hottuning exhaust manifold is bolted onto the head…… but will need a little bit of manipulation to get the 2 into 1 section to fit  8O .  Thanks Ansar for the gear linkage bushes, fitted most of them and also purchased the diagonal and short linkage to the gearbox….I now have a very tight feeling gear stick  :cheer: .  I've gone and removed the water cooled oil cooler and fitted the 8v air cooled oil cooler, for no other reason than i can  :twisted: .

Removed the servo and fitting the Corrados servo and master cylinder (with reservoir bottle turned round to give plenty of clearance on the dizzy cap, though not that it needs it, as I've fitted the dizzy cap from a Talbot Samba, but may just go and fit an ABF cap when it gets closer to finished.
I tried to see if the original alternator from the DX engine would fit on the 16v using the DX mounting braket…..but once fitted I found there was no room for adjusting the alternator, so gone and fitted the 16v's alternator back on, just going to be having to sort out the pulley for running the water pump next, tried the pulley from the DX engine but it doesn't seem to line up with the run of the alternator pulley (so will come back to that problem soon)
With the Master cylinder and servo removed, I've also taken the oppurtuning to chuck a bit of hammerite into the nooks and crannies and will be making some new brake pipes up when the 'T' pieces arrive to make up for the lack of outlets on the 16v master cylinder.
Another thing I will be interested to see will be how close the pipe from the throttle body will be to the brake reservoir bottle, will find out this weekend   :pray:

Will hopefully get some photos up this weekend and some more updates  8)

Hi, ive just started a KR conversion in mine and am after a manifold.  How have you found the hottunning version, fit and all that.  Also did it come with the straight connection down pipe.  

Keep the updates coming, i will be watching this, ive got all this to do on mine !!

Cheers

Ste