Mars Red 2Ltr 16v Build

Hi chaps,

I started this conversion a long time ago now, and have been distracted by things like finishing Uni, starting a new job, moving away etc.

I have just secured a garage closer to where I live now, so should be able to finish the project and start driving her again.

The car started out when I bought it as a 1.8 8v campaign with a few mods including:

- Eiback & Koni suspension -40mm
- Lower front strut brace
- 280mm front discs using spacer brackets
- 15" BBS RA wheels
- K&N Panel filter
- Large bore S/S exhaust system
- Four branch exhaust manifold

The engine was getting pretty tired at 150,000 miles so I saw fit to give it a new powerplant, something a bit tasty.

I went for the ol' tried and tested 9A 2ltr 16v conversion, so I went about sourcing this from a guy in Buckinghamshire for around ?300 if I remember rightly, and started to purchase things that I knew I would
require.

Luckily on my placement year at Uni I worked for Caterham Cars and the guy who builds the engines there ported, polished and refurbed the head to give it a few more ponies.

So far I have bought and fitted most of the following:

- 9A engine
- Ported and polished cylinder head (engine guy at work)
- KR Cams
- 4 into 1 stainless exhaust manifold (storm developments)
- New braided fuel lines (crazyquiff)
- 16v servo and master cylinder with new brake lines in engine bay (Ebay)
- New shiney sump pan
- Poly Steering rack bushes

As you can see from the photos I have fitted the engine and gearbox, and need to connect up driveshafts, install the fuelling and ignition system and plumb the engine up. Also sort the exhaust system out.

Oh and also put a new engine mount in cos I cracked the drivers side one when I was putting the engine in…doh…

I am sure there is more that I have forgotten, but take a look at the pics.

Any comments are welcome.

I will try to update as possible.

Cheers,

Bob.

When I bought it


New shiney bits





Engine Out




engine free to any takers


Painting some bits



Engine building








Engine going back in

Looking good mate that's awesome that you're attempting it yourself!!  And what a placement Caerham was  

Keep the updates coming!!!

Nice one, what box, shafts, ecu, wiring etc you using? Keep the updates coming

Looks really good fella, finish on the rocker cover is great! I'd love to relieve you of that engine, but a bit too far away for me this month

Mat

Thanks for the replies chaps,

I am using the standard mk1 GTI 'box with all new seals etc. (only god knows how long that will last) which means I can use the standard drive shafts etc.

I have both KR ECU's which I will be comparing when the car is running, coupled to this is the MK2 16v engine loom.

The engine is located in Orpington, Kent if you are interested in taking it off my hands.

Also if anybody is interested this car was featured (not when owned by me) in practical performance car way back when.

I will try to update soon.

Bob.

Bob.

The 020 is as good a box as any, the weak point being the diff rivets. Peloquin used to do a diff bolt kit but this has now been taken over by ARP. Worth considering if your intending to keep the car.

what paint did you use on the valve cover??

Looks great!

A word of advice regarding the waterpump pully though; the outer pully (to drive the PAS pump) acts as a retainer for the slipper clutch mech on the main pully. I made the mistake of removing it (I also tacked the outer joint) and narrowly avoided a huge pully-to-engine bay catastrophie when the whole lot seperated 8O

Get yourself a pressed non-PAS one on there if I were you  :wink:

All the best!  

Cheers for the advise mate,

I realised that I needed a new pulley shortly after I took these pic's, I managed to source a new MK2 16V non-pas pulley to remedy the situation. It turns out not alot of dealers or breakers know that the MK2 came with no pas!? cos it was a bugger to find.

The paint I used for the cam cover was just a halfords high temp spray on jobby, I dont really like the texture of it but it looks OK, I was going to get it red crackle coated like Ferrari's and the like but went for this method for ease.

Yea I did think about doing the diff bolt fix but didnt get round to it, I will probably source another 'box at some point and prepare it, then fit that when the clutch needs changing at a later date.

I am due to tackle the fuel system soon, does anybody have any experience in what parts to use from what car? ie. metering head, WUR (where to get this from?), 5th injector etc?

Cheers,

Bob