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8v tuning project - 158 HP (On for paint!)

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8v tuning project - 160+ HP!

2,0 AGG conversion, G60 PG

Is it a Complete 2.0 Engine?


Posted at work…

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Don't sweat it Hurtig we're still here!

Just waiting for the performance figures and a bit of footage of her driving around.:ocf_emoticons__scooter:The detail on the engine and the bay is excellent and the RM's always look goood… incidently what width lips did you end up going with front and rear ?

Keep at it… not long now :thumbs:

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figti said

Is it a Complete 2.0 Engine?

Posted at work…


It is a 2 litre bottom from a 1997 VW Golf :)

The head is from a 1,8 G60 from a Corrado.

It means some adaptations to the timing belt covers, mounting of the mk1 alternator etc.

1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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ConvictGTI-No.1983EW said

Don't sweat it Hurtig we're still here!

Just waiting for the performance figures and a bit of footage of her driving around.:ocf_emoticons__scooter:The detail on the engine and the bay is excellent and the RM's always look goood… incidently what width lips did you end up going with front and rear ?

Keep at it… not long now :thumbs:

Haha .. Good to hear :)

It is always great with some feedback from you guys.
Especially if it is not done to your taste, or if there is something, that I should be aware of.

Sadly the engine bay gets more and more messy, as I progressively keeps adding more bits. The wish to get the car driving overshadows the wish to keep it looking tidy :( I want it fired up and get it going and then I can later change details in the bay, that I do not like.

Looking back I should have had all the small brackets and bits sand/glass blasted and then sprayed. I am not satisfied with the finish that I have got with rough sanding and then just sprayed with rattle cans.

Status is now, that everything is almost done. Got some good things done today:
- Fuelpump relay fitted and fuelsystem wired.
- Webers and inlet manifold fitted (with rough jetting)
- Stainless 4-branch manifold fitted (wrapped)
- Alternator and belt fitted (pain in the ass)
- All fluids added (gearbox oil, coolant, oil)
- All loom wiring refitted to engine and sensors

I though still need to fit:
- Clutch cable
- Throttle linkage/throttle cable
- Ran out of rubber fuel line :(
- Driveshafts

Sadly my startermotor seems shot :(
When turning the key, the starter just clicks once.
I am confident that the cabling and ground is OK and that the battery is fine. I therefore ordered a new starter.

Not long untill I can fire her up :)

1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Not really any good pictures from today ..

Found out, that the alloys on my GTI Campaign project, are genuine VW "Snowflake" winter alloys.
Quite like the design of them and have decided to refurbish them.

image.jpeg image.jpeg image.jpeg image.jpeg

1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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8v tuning project - 160+ HP!

Hurtig said

figti said

Is it a Complete 2.0 Engine?

Posted at work…


It is a 2 litre bottom from a 1997 VW Golf :)

The head is from a 1,8 G60 from a Corrado.

It means some adaptations to the timing belt covers, mounting of the mk1 alternator etc.
Cool.. The Same as i still create/Built..

I have a 2e bottom, 2e alternator, PG "p" Full Head, audi Abk throttle (Drosselklappe) And ABK Chipunit (Steuergerät)
Still Plan a 268 schrick at least..

What did You Plan?

Reg Kevin


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8v tuning project - 160+ HP!

The small Filter is no good idea.. I still use it in the past too.. Make only Problems..  The Headcover is no PG G60 one.. You Know it?

Look my:




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So … many, many months later, without much posting here ..

IT'S ALIVE!  :wub:

Car has been running for 3 full months and has passed Danish MOT, which is very strict = success  :thumbs:  :cool:

It ended up with slightly dissapointing 156 HP. This is mainly due to the venturies in the Webers, which are still the standard ones (36mm I think). There is definately more power to gain if the engine gets to breathe more :) Another cam in the 300 degree range is also very tempting.

On the road the car is extremely quick and has the awesome and distinctive 8 valve vs Weber sound. On the rolling road it is tweaked for maximum driveability and is a dream to drive - even in traffic in the city :wub:

Images are the ones I have from my phone - nothing fancy …
IMG_0126.JPG IMG_0127.JPG IMG_0164.JPG IMG_0165.JPG IMG_0186.JPG IMG_0284.JPG IMG_0523.JPG

1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Beautiful looking car and engine bay, well done  :thumbs:

Matt

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looks like a real pro install there mate
I home tuned a 8v engine a while ago they really do fly of the mark
simple to work on old skool tuning  :thumbs:
1900 bottom end
1800 head with pnp kent cam and pully
audi big throttle body
matched inlets
gave great cheap thrills
yours is a lot better job
nice one

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pazwaa said

Beautiful looking car and engine bay, well done  :thumbs:

Matt

Thank you very much  :wub:

The car needs a respray though, as the front is now in a great color, and the rest is just faded old paint  ;) But most importantly it is running.

1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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vwoldmad1 said

looks like a real pro install there mate
I home tuned a 8v engine a while ago they really do fly of the mark
simple to work on old skool tuning  :thumbs:1900 bottom end
1800 head with pnp kent cam and pully
audi big throttle body
matched inlets
gave great cheap thrills
yours is a lot better job
nice one
Thanks  :wub:Not really very pro - just a steap learning curve! Think I hit just about every possible problem. But I guess that is the beauty of it. I definately like it more because I built it myself  :)Sounds like a great build - what power did your engine produce?

IMG_0020.JPG IMG_0021.JPG IMG_0022.JPG IMG_0023.JPG IMG_0024.JPG IMG_0025.JPG IMG_0026.JPG

After the first run the engine/cam actually seized completely  :oThere was good oil pressure at the bottom and at the oil filter console, but not in the head, which caused the cam to seize on the last bearing. This meant I had to pull the engine out again and start all over.
That sucked big time  O_oIt was due to the Cometic steelgasket being to thin.
We calculated that not enough oil was able to flow to the head at idle, so we had to make a bigger groove in the head, which sorted the problem.

1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Luckily we were able to polish both the cam and the camshaft bearing. I was afraid that the nice head was shot after all that trouble with porting, new valve guides, valve seat work etc  :thumbs:Also I found that the distributor was toast.
We sent it to be completely refurbished at a specialist and had the timing done according to our desired specs.

Still it was not able to handle the proper ignition advancing, so I fitted a special Lumenition electronic ignition (infrared) with coil and CEM power module etc.

1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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I can totally understand it getting messy in the bay as you rush to get it on the road, but that looks lovely- the engine bay I mean. The car is great, but I like how clean and shiny and puts purposeful everything is under the bonnet.

Also well done for chasing drive ability and a nice wide spread of torque, not just "pub figures" as we say here.

ETA- oh wow, just read your update! Hope it's healthy again now!

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polynesian said

I can totally understand it getting messy in the bay as you rush to get it on the road, but that looks lovely- the engine bay I mean. The car is great, but I like how clean and shiny and puts purposeful everything is under the bonnet.

Also well done for chasing drive ability and a nice wide spread of torque, not just "pub figures" as we say here.

ETA- oh wow, just read your update! Hope it's healthy again now!


 Thank you very much :)

IMG_0236.JPG  I fitted a GTI duck spoiler, which normally gets smashed, but which at least looks great untill then ;) 

Also fitted a RPM-gauge, as the original one is shot. Looks great in the holder to the left. Also notice the 3 x VDO gauges in the centre console.

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1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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So what is this ..?

Prepping for paint :)

LA3A - Mars Red

Some minor spots of rust needs to be grinded down. The lover stone guard though have to be replaced. Found some rust in the A-pillar in the doorframe, a little under the left rear light and a little between the licenseplate lights.
Also discovered a nasty spot under the rear washerfluid bottle, where liquid has been able to sit, because of a leaking seal of the pump. Did not look very pleasant at all, but will be sorted! IMG_0345.JPG

Overall she is in a very good shape though. IMG_0348.JPG IMG_0349.JPG IMG_0350.JPG IMG_0351.JPG IMG_0353.JPG IMG_0356.JPG IMG_0359.JPG IMG_0363.JPG IMG_0364.JPG IMG_0365.JPG IMG_0366.JPG IMG_0367.JPG IMG_0368.JPG

1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Got a great deal on some nice Recaro GTI Edition seats from a MK3 GTI.


 

The comfort is absolutely sublime - love these seats.

Seatframes will be adapted to fit an GTI cloth fitted to the centre.


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1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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"Got a nice kit of hose clamps, that I just had to have"

This looks like a great kit - where did you get them from? I can see 'probuilder' but cant find them on google?

Cheers, great looking project so far.

 :thumbs:  

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Baggins said

"Got a nice kit of hose clamps, that I just had to have"

This looks like a great kit - where did you get them from? I can see 'probuilder' but cant find them on google?

Cheers, great looking project so far.

 :thumbs:  


Thank you  :)

I bought the clamps from a Danish DIY shop:
https://www.bygmax.dk/probuilder-spaendeband-ass-m-skruetraekker.html

1982 - Mk1 Golf 2.0 AGG 8v - 158 HP / 202 NM

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Hurtig said

Baggins said

"Got a nice kit of hose clamps, that I just had to have"

This looks like a great kit - where did you get them from? I can see 'probuilder' but cant find them on google?

Cheers, great looking project so far.

 :thumbs:  


Thank you  :)

I bought the clamps from a Danish DIY shop:
https://www.bygmax.dk/probuilder-spaendeband-ass-m-skruetraekker.html


Thanks  :thumbs:

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