GolfGTIforum.co.uk
Model specific boards => Golf mk4 => Golf mk4 gallery => Topic started by: jv on 23 December 2008, 10:27
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:)
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Thanks Jv :afro:
Right after being unable to sell my 2.0 and a motorcycle accident which trashed my bike i decided that i love my MK4 but not the power so i used the money of selling my bike as salvage (and most importantly having permission from the wife) to do a 1.8t conversion
:cool: i scoured ebay and the local adtrader and the forums for the engine/box/loom/ecu etc, could find plenty of AGU codes but very few AUM. I wanted a AUM as it has drive by wire throttle same as the 2.0, where the AGU is cable basically i didnt want the hassle of installing the pedal box and drilling the bulkhead to fit the cable. so i just about gave up looking for engines as most breakers dont give warranty on the engines if there used for conversions and as i would be buying an engine i didnt know if it ran. so the 2.0 was nearly on it's way to the auctions. :cry: :cry: but then ollie d posted his was for sale damaged, so i took the plunge and thought bugger it lets spend the extra and buy the whole car. :wink: so thanks to ollie d, and a big thanks to rhyso for driving me all the way to surrey to pick it up. so after crimbo will be starting the swap :cool:
so here is a photo of the 2.0 .......
(http://i233.photobucket.com/albums/ee76/dai-cymru/007-3.jpg)
and here is a photo of the donor vehicle.......
(http://i233.photobucket.com/albums/ee76/dai-cymru/IMG_12791.jpg)
so i will update this thread as and when things happen :smiley: :smiley:
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Spent hours cleaning the garage out today to get project turbo in so this was it's last drive as Y286 and it's backed in ready for strip down :smiley:
(http://i233.photobucket.com/albums/ee76/dai-cymru/front.jpg)
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Day 1 3rd Jan 09
first day on the turbo project, first job was to remove both doors, bonnet and tailgate to aid space in the garage so we could get inside without struggling past the doors.
First Off BIG THANKS :afro: to my 2 mates Rhyso & Bob for helping out on the project
heres the team
Rhyso chief interior removal aka golf geek guru (i helped for 2 mins and broke the centre console as trim isnt my strong point)
(http://i233.photobucket.com/albums/ee76/dai-cymru/IMG_1295.jpg)
Next Bob Chief electrician and all round stench master farts constantly (thank fook cos there are sh!t load of sensors to unplug for the loom
(http://i233.photobucket.com/albums/ee76/dai-cymru/IMG_1294.jpg)
And finally me Chief monkey fitter
(http://i233.photobucket.com/albums/ee76/dai-cymru/IMG_1293.jpg)
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First some pics of the doors and tailgate removal and last time donor drove under her own power :cry: RIP
(http://i233.photobucket.com/albums/ee76/dai-cymru/011-2.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/012.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/013.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/015.jpg)
And Rhyso the lowrider
(http://i233.photobucket.com/albums/ee76/dai-cymru/016.jpg)
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(http://i233.photobucket.com/albums/ee76/dai-cymru/IMG_1298.jpg)
and finally at around 9.30pm (we didnt start til 3 on the engine) the exhaust to turbo nuts were really tight and eventually sheared after mutch swearing at them and then we had a twit of a job with the drivers side driveshaft. we also found that whoever done the turbo job was a bit of a butcher and destroyed most of the wiring conectors and just cable tied stuff up :angry:
engine out (we dropped it onto a bread crate :grin: :grin:)
(http://i233.photobucket.com/albums/ee76/dai-cymru/IMG_1301.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/IMG_1302.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/IMG_1304-1.jpg)
we were happy to see it out as it was -3 and we were fecking cold :sad: :sad: but our target for the day was achieved :smiley:
we also renamed the project to project traffic cone after mine and bobs work overalls made for difficult photo ops
(http://i233.photobucket.com/albums/ee76/dai-cymru/018-1.jpg)
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right made a slight error with the wiring loom didnt realise it seperated on a plug and thought the washer bottle, abs wiring, headlights etc etc so spent about 3 hors this morning stripping it all out and then we found the plug :embarassed: :embarassed: but nevermind took the ecu out too, we then towed the car out and swapped it over with the red golf. took a fe pics of the swap out, i also put the camera down and thought it got pinched but then only just found it so the 2.0 engine is nearly out all it needs is the exhaust downpipe unbolting, the clutch slave cylinder undoing then it's out sorry no pics as thought camera had gone, :embarassed: will get some tomorrow.
(http://i233.photobucket.com/albums/ee76/dai-cymru/004-4.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/005-3.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/006-4.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/007-4.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/008-4.jpg)
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right got the 2.0 out today alsdo used an engine hoist this time as we only had one bread crate :smiley:
(http://i233.photobucket.com/albums/ee76/dai-cymru/001-7.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/002-7.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/003-4.jpg)
also swapped the ecu's over so the turbo one is in the 2.0 ready to go
(http://i233.photobucket.com/albums/ee76/dai-cymru/004-5.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/005-4.jpg)
not much will happen for 7 days no as im on shift for 7 days but will try and get the parts i need ready and the studs out of the turbo and get the timing belt swapped over :smiley:
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well with this little gem of a tool i won the fight of the stud removal and managed to get them both out :smiley:
(http://i233.photobucket.com/albums/ee76/dai-cymru/014-1.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/015-1.jpg)
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70 hour shifts now over so back on the car today :smiley: had a bit of running around today so started on the car late morning first job was to get the drive shafts out as they need swapping over and the 2.0 ones are too long to allow the engine to go in, so did that, then tried to land the engine on the mounts but couldnt get the nearside mounts to line up, with a bit of head scrathing and a look at what was stopping it turns out that the anti roll bars are different shape and the 2.0 ARB was straight instead of flat so engine back off the offside mounts and out the way then had to drop the subframe and pull the ARB out then had to go out and swap the one out of the turbo :cry: but thank god i have the donor car :smiley: :smiley: anyway got engine back in and mounts on :smiley:
(http://i233.photobucket.com/albums/ee76/dai-cymru/005-7.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/004-7.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/006-6.jpg)
Dogbone mount fitted too
(http://i233.photobucket.com/albums/ee76/dai-cymru/011-3.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/008-5.jpg)
also had to swap these 2 over as the heater matrix feed and return are different for the 2.0 to 1.8T
this the 1.8t ones swapped over
(http://i233.photobucket.com/albums/ee76/dai-cymru/003-6.jpg)
also had to fit the intercooler bracket
(http://i233.photobucket.com/albums/ee76/dai-cymru/010-6.jpg)
you can see the shape of the 1.8T ARB
(http://i233.photobucket.com/albums/ee76/dai-cymru/013-1.jpg)
this is the 2.0 one totally flat
(http://i233.photobucket.com/albums/ee76/dai-cymru/014-2.jpg)
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(http://i233.photobucket.com/albums/ee76/dai-cymru/002-9.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/003-7.jpg)
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DOH!!!!! cant get the car running the immobiliser is causing me a headache i have swapped the ecu clocks ignition barrel and keys over and the immobilser still cuts in and cuts engine out, so anyone know how to sort this :sad:
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Im sure R-Tec Nick will know you got it in there quick enough though mate :cool:
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Im sure R-Tec Nick will know you got it in there quick enough though mate :cool:
funnily enough rhyso has spoken to nick and my ecu is off to his magic hands to sort out so hopefully by the weekend it will be running!
:smiley:
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Result fingers crossed then mate :cool:
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no pics but fitted the intercooler today and bob split the 2.0 loom and wired in the missing plug for the secondary air pump i also bled the brakes and clutch today :smiley: also removed the exhaust from the donor (had to cut the rear off as still original and was running over the axle) ECU is hopefully back on monday thanks Nick :afro:
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ECU came back yesterday but the car still wont run dont know whats wrong with it, seems the immobiliser is still cutting in for some reason :cry: :cry:
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:cool: :cool: :cool: :cool: :cool: :cool: :cool: :cool: :cool: :cool: :cool: :cool: :cool:
had the ECU, clocks and keys back from a guy on UKMKiv's today Thanks ARD he recoded all the gear for me, i put it back in the car today and with clenched butt cheeks (was so worried it wouldnt work cos of the problems i have had) and low and be hold
IT'S RUNNING :cool:
also big thanks to rhys for spending hours searching the net for soloutions and posting all my stuff to ard to sort out.
also did i say
IT'S RUNNING :grin:
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righto after stripping the shell and my front drive looking like a scrap yard it was time to say goodbye to the turbo shell forever
(http://i233.photobucket.com/albums/ee76/dai-cymru/001-11.jpg)
bet you havent seen a flying mk 4 before !!!
(http://i233.photobucket.com/albums/ee76/dai-cymru/002-12.jpg)
(http://i233.photobucket.com/albums/ee76/dai-cymru/003-10.jpg)
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Right bit of a update, Got new CCM and fitted it, still didnt work spoke to ARD over on ukmiv's and he sussed it out, i fitted the immob 2 clocks and my car is immob 3 :sad: so got ARD to recode my immob 3 clocks to work with the immobilser, This guy is a legend he put auto windows on and miles to empty on the clocks he knows the MK4's electrical systems so well so big cheers ARD :afro: and big cheers to rhyso and his vagcom for coding it all in so i can now disable my alarm open my windows start the car and adjust my mirrors all with one key :smug:
also fitted the tip today bit dissappointed that it has a extra hole thats not needed (so much for engine specific) so looks a bit pants with a bolt in it, i did put a shiny cap bolt in it to make it look a bit better, but the tip hasnt solved the running prob :cry: :cry:
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Finally sussed out the running probs: actually did it on the 27/03/09 but forgot to update anyhoo@@
Stripped it all down with the idea of fitting a new map and spotted some chaffed wires in the map loom so then my lecky mate bob pulled a bit further up the loom and it came away in his hand (some prick had wrapped the wires together with black tape), I had to take the intercooler off as the screws were seized solid in the intercooler holding the map sensor in. So we Put it all back together after some serious soldering from bob as he ran a new section of loom in. Started in the depot still running like sh!t and overfueling drove it about a 100 yards and she came alive :cool: :cool: :cool: :cool:
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Made it to the Rtech Rollling Road and made 179bhp at the flywheel and 146bhp at the wheels 2 fault codes arose
2 Faults Found:
17963 - Charge Pressure: Maximum Limit Exceeded
P1555 - 35-10 - - - Intermittent
17705 - Pressure Drop between Turbo and Throttle Valve (check D.V.!)
P1297 - 35-00 - -
Nick said it's dropping off top end and may have a boost leak will look for it when i get around to it. I cant feel it on the road so im just going to enjoy it for now. ordered some aero front wipers and a MK V rear wiper (more to the point rhyso ordered them for me) should be here by the weekend :smiley:
pinched T_J_G's photo of my car on the rollers :smiley:
(http://i233.photobucket.com/albums/ee76/dai-cymru/DSCF02611.jpg)
also notice the golf gti plate holders :smug:
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Bought some Aero wipers for the front from VW
Before:
(http://i233.photobucket.com/albums/ee76/dai-cymru/003-14.jpg)
After:
(http://i233.photobucket.com/albums/ee76/dai-cymru/004-10.jpg)
And a mk V Rear aero wiper
Before:
(http://i233.photobucket.com/albums/ee76/dai-cymru/001-15.jpg)
After:
(http://i233.photobucket.com/albums/ee76/dai-cymru/002-15.jpg)