mk2 gti engine conversion, at home!

Discussion in 'Mk2' started by weide41, May 19, 2011.

  1. weide41 New Member

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    hi guys, im new to this forum but like you guys i love mk2 gti golfs, im 22 and live in bristol and back in nov 2010 i purchased a mk2 1989 8v gti golf for a real steal and within 24 hours off buying it i saw someone who had done a mk4 gti 1.8t 20v engine conversion. like a lot of us i was wondering how i would be able to do it myself as i only had the basic garage tools and although i knew a little about mechanics this is a hole different ball court. but me being me i jumped in at the deep end.

    as i am self employed i decided to go part time for 2 months to achieve this conversion. at the moment i am in the 4th week, working on it 4 days a week and i thought that i should share all that i have learned with you fellow mk2 followers.

    i have also decided to put a mk4 golf dash bored conversion aswell.

    to start off here is a list off some parts you need to achieve this conversion, here goes,

    • mk4 golf gti 20v 1.8t agu engine and gearbox
    • mk4 golf cable gear linkage
    • mk4 golf dash bored and switches etc
    • mk4 golf heater matrix with air con
    • mk4 golf dash bar
    • mk4 golf wiring loom, clocks, ecu, key etc
    • mk4 golf air con pipes, rad pipes etc
    • mk4 golf air con rad
    • mk2 golf 16v rad
    • mk4 golf steering column
    • aftermarket slimline 10" rad cooling fan
    • bmw battery cable, (engine to boot)
    • mk2 golf front and rear engine mounts
    • mk3 golf gearbox mount
    • mk4 golf down pipe
    • aftermarket front mount inter cooler
    • checker plate
    • 3mm steal sheet ( to replace any rust you may have)
    • good-ridge 6 line stainless steel brake hoses
    • power flex bushes ( anti roll bar, sub frame etc)

    i have decided to go all out and replace most of the front end with new parts and when i can afford ot i am getting corrado hubs and 300mm wilwood calipers.

    i will try to upload some pic asap

    pete
     
  2. weide41 New Member

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    can any one tell me how to add photos plz

    cheers
     
  3. lard44 Forum Member

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    Upload them to Tinypic, Imageshack or similar and then simply copy the links across, making sure to include IMG tags around them.

    If this doesn't happen automatically then click on the icon in the reply bar that looks like a 3 year old drew the pyramids.
     
  4. weide41 New Member

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    [​IMG]

    [​IMG]

    smoothing out the engine bay
    [​IMG]

    [​IMG]

    me with the dona mk4 gti
    [​IMG]


    dona engine, 98,000 mile 20v 1.8t agu
    [​IMG]

    removed all ancillaries to tidy up the engine and check valve clearness
    [​IMG]

    will upload more pics soon
     
  5. dub-addict Forum Member

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    London
    I use Photobucket.com its really easy. just sign in upload a picture.

    after uploading the pic;

    - Click the IMG (image) code below the picture (it copies itself as soon as you click it with your mouse).

    - Then just paste the code below the text or wherever you want the picture to be.

    - then press preview thread, just to make sure it has worked.

    Hope this helps :)
     
  6. weide41 New Member

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    [​IMG]
    trimming mk4 dash, needed to take off about 2 1/2 inches so it would fit without being cramped when sat in it.
    [​IMG]
    trimming dash bar to size
    [​IMG]
    welding in dash bar with a welder i bought for 30 from a second hand shop. bargin, cheaper than the 200 a mobile welder wanted.
    [​IMG]

    its in, 2 days off going round and round like a yo yo, the first time i put it in it was to far out, but by trimming bit off slowly it went in snug
    [​IMG]

    engine bay all primed up with the heater and air con pipes installed
    [​IMG]

    mk4 heater matrix fitted
    [​IMG]

    after 5 hours my mate finally got the wiring loom out, when i saw it i could not believe i had the reinstall that! were do i start!!!
    [​IMG]

    [​IMG]

    i cut out a hole in the bulkhead to feed that mass of wire though, now its all in i will have to weld it back up
    [​IMG]
    welded up and filled over
    [​IMG]
     
  7. Gaz37 The Grouch. Paid Member

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    Looks like that's coming along nicely, well done:thumbup:

    What part of Bristol are you in? (PM me if you'd rather not stick it on the forum)
     
  8. weide41 New Member

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    got some more pics for ya,

    wiring in the dash unit, even roped my girlfreind and sister in to help,
    [​IMG]

    [​IMG]

    [​IMG]

    altough this will look clean, i have decided to get rid of the seem sealer and smooth out the engine bay
    [​IMG]

    i hope it will be worth while
    [​IMG]
     
  9. turnipmuncher Forum Member

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    Good stuff matey..... maybe resize the images before you upload them if you can? If not you may be your able to set the size of the image on the camera to a smaller size?

    Keen to see all the pic's but loading v.slowly..... Good luck with the project!
     
  10. weide41 New Member

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    [​IMG]
    [​IMG]
    all primed up and first coat of paint, i have chosen the ford focus rs
    ultimate green for the engine bay
    [​IMG]
    after polishing up the alternator, p/s pump, inlet manifold, air con pump and oil cooler
    and painted the engine with Matt black engine lacquer, replaced all the gasket, new cam belt, new plugs its almost ready to fit
    [​IMG]

    [​IMG]
    polishing the bits took 2 days, but it was so worth while, oh and dirty as you can see by my face
    [​IMG]
    engine bay finally painted ( with rattle cans) i am so glad that i smoothed it out, i think it looks 10 times better
    [​IMG]

    [​IMG]
    steering rack all painted up, new wishbones, bushes, ball joints etc, now ready to install
    [​IMG]
    steering rack connected
    [​IMG]
    engine with 5 speed mk4 gti cable change box fitted
    [​IMG]
    its in, i think it looks so much better than that old slugish 8v.
    [​IMG]

    [​IMG]

    will add more pics soon.

    i have learned so much in the last 4 weeks since starting this and though
    watching countless hours off you tube vids and ready both the mk2 and mk4 haynes manuals i think im finally starting to get somewhere.
     
  11. welshwizzard88

    welshwizzard88 Forum Member

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    Looks good mate.

    I know the feelng about videos and build threads.

    Are you using all of mk4s wirring or are you going to splice it into mk2?
     
  12. weide41 New Member

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    hi buddy, i decided that it would be easier if i took everything mk2 out, i bought a complete mk4 gti golf to be the dona so i have put the whole wiring loom from that in.

    the front end mechanically and electrically is all mk4, apart from the drive shafts, sub frame etc.

    the only thing i am regretting is putting in air con, finding space for the rad, fan, pipes etc is proven to be hard as i am trying to have as bare of an engine bay as i can.
    the battery is going into the boot so i bought the battery cable of a bmw because most of them have the battery in the boot so i would be guaranteed that i would not loose voltage.

    cheers
     
  13. Christian1402 New Member

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    not a bad effort there mate!

    i did my engine in a barn haha, wasnt a 20v though allthough wishing i did it now. still a 2.0 16v is still a big power hike from the 1.3
     
  14. limbo118118 New Member

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    loving this thread matey! keep it up!, im doing exactly what you are, i know abit about engines etc and just got my 1st mk2 4 weeks ago, hopefully getting a donor golf mk4 or audi etc etc very soon to do this! think i might have to start a thread like this! :) great job tho! gives me convidence haha
     
  15. Richard Mk2

    Richard Mk2 Forum Addict

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    Location:
    London / Buckinghamshire
    Any updates on this ? Great read so far, top work :thumbup:
     

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