GolfGTIforum.co.uk
Model specific boards => Golf mk4 => Golf mk4 gallery => Topic started by: F17BAD on 11 February 2012, 00:02
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Well this one goes like this..
Back in 2000 my dad bought this Golf GTI.. it was intended to be the last car he ever buys...
Fully loaded, leathers, climate, metallic black, 17inch santi monica Etc Etc/
He chose the dreaded 2.0 8v, bear in mind he got this car when the MK4 was relatively new out.
The 2.slow has lived up to its reputation of been sh!te.. he has always serviced the car on time and at the dealer.. at 80k it had to have a full engine rebuild due to a known fault with the pistons this engine suffers from (uses lots of oil, oil in the spark plugs....)
this was carried out at a specialist VW garage 3 years ago and i got all the parts needed from my contact at the dealer (at a cost of £640 with my discount!!)
well guess what... the exact same problem has returned
Current milage on the car is 127 000k
His options were to break the car
buy a new car
convert the 2.slow to something decent
i went with option 3.
i Sourced AUQ (same as the Mk4 Anniversary has) This one came from a yellow Seat Leon Cupra which had been in a light rear end.. the car drove spot on and i have the FSH for the car, HPI report, all old bills and even the MOT which runs out September 2012!!!
from the donor car i took the following for the conversion
Engine (covered 90k)
Full Looms
ECU
6 Speed gearbox
Gear linkage
Hydro pipes for 6 speed
6 speed Driveshafts
OEM side mount intercooler
DBW pedal and loom
airbox
all ancillaries etc
Cat / Downpipe / Turbo (K03s)
I had the Turbo inspected as it was passing a hell of a lot of oil
turns out the seals were all fooked so my mate gave it a full refurb, the fixing studs had also snapped off so they had to be drilled out!
he did a £400 job for mates rates (£70)
The engine had a nasty oil leak from the Half moon seal (common on 1.8T) so i got about degreasing the lump and fixing the leak
Replaced as follows:
(All genuine parts form the dealer)
Cam tensioner seals
Cam cover gaskets
Spark plug gaskets
Spart plugs
Oil pick up pipe
Sump Gasket
Gearbox oil
Engine oil (full synthetic)
oil filter
Air filter
Coolant
various pipes
Various gaskets
Various bolts
Secondary air pump piping
Waterpump
Cambelt
Aux belt
Clutch kit (3 part kit including slave cylinder)
MAP sensor
MAF sensor
DV (to be changed to forge)
I also fitted a Jetex exhaust, i sprsyed the flat part of the rear of the box black as it shows from behind the car on the mk4 and i wanted a factory feel to it (or as much factory as i could)
Anyhow here are various pics from the conversion
This took us 2 days to complete
How it all began
The Donor car:
(http://img210.imageshack.us/img210/7885/imagehtt.jpg)
The AUQ (after a massive amount of degreasing )
(http://img24.imageshack.us/img24/3033/imageiku.jpg)
German engineering... Nice
(http://img16.imageshack.us/img16/8232/imageimy.jpg)
(http://img23.imageshack.us/img23/4508/imagegpg.jpg)
(http://img24.imageshack.us/img24/2782/imagezykr.jpg)
another 8v off the road:
(http://img859.imageshack.us/img859/591/imagekmt.jpg)
Another bay ready to be cleaned!!
(http://img268.imageshack.us/img268/1696/imageidm.jpg)
Full engine undercover
(http://img96.imageshack.us/img96/8365/imagedhk.jpg)
OEM Intercooler located
(http://img600.imageshack.us/img600/6872/imagecpw.jpg)
AUQ meets its new home
(http://img36.imageshack.us/img36/2246/imagedxq.jpg)
(http://img705.imageshack.us/img705/2712/imagewwz.jpg)
Here is the part i painted black
(http://img843.imageshack.us/img843/9039/imagezys.jpg)
(http://img269.imageshack.us/img269/581/imageswq.jpg)
The Turbo..
before refurb:
(http://img718.imageshack.us/img718/8169/imagewjf.jpg)
After refurb
(http://img849.imageshack.us/img849/9813/imagezdeg.jpg)
(http://img205.imageshack.us/img205/1071/imagezac.jpg)
New studs
(http://img35.imageshack.us/img35/4563/imagecis.jpg)
shiny
(http://img832.imageshack.us/img832/5517/imageodr.jpg)
All finished:
(http://img193.imageshack.us/img193/3879/imagedoal.jpg)
(http://img542.imageshack.us/img542/4645/imageois.jpg)
(http://img59.imageshack.us/img59/1467/imagekjog.jpg)
(http://img826.imageshack.us/img826/9282/imagejix.jpg)
(http://img806.imageshack.us/img806/2300/imageazt.jpg)
Going to go see Nick from Carbon for a cheeky Remap :-)
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Awesome work :afro: looks like it left the factory as a 1.8t
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good work :)
wish i had the money/ability to do that :angry: :grin:
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cheers
not had much time to post on here recently due to all this work on cars!
My dad is absolutely over the moon with this!.. it is a great drive now
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Awesome stuff that engine looks absolutly pristine! :cool:
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Awesome stuff that engine looks absolutly pristine! :cool:
thanks man
i have spent a lot of time on the engine, did not look like this when it was in the donor car LOL
not quite as mint as the engine in my golf but TBH neither are engines in brand new cars :evil: :laugh: this is not a show car and my dad didn't want any parts painting.. so i had to get very busy reviving the finish best as i could.
I have cleaned every part on this engine including all pipework etc, iv basically gone to town on it, same applies to service parts
But i treat every conversion we do the same... we basically don't just throw them in the bay!
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Bangin out another one!
Looks top notch dude, well done
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Bangin out another one!
Looks top notch dude, well done
Cheers mate ;-)
Keeping us busy these conversions lol
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Superb stuff mate, every time i see one of your engine swaps I'm impressed.
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i need to get my ass to college and learn to be a mechanic as i would love to have the talent you have mate very impressed with the workmanship its spot on
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2 days? :lipsrsealed: thanks for the mention. :kiss:
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Double post
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Haha
Big shout to my brother from another mother Russ for the vag com and help with a wire the mk4 didn't have
Basically Russ over the phone checked his diagrams and quickly helped me out
Also sent me a fully working vag come to code the ECU which arrived the next day!
He is a star and needs to move up north fast, he is one of the only guys who's input I trust :-)
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top work brad :cool:
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Great work as always Bud :afro:
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Haha
Big shout to my brother from another mother Russ for the vag com and help with a wire the mk4 didn't have
Basically Russ over the phone checked his diagrams and quickly helped me out
Also sent me a fully working vag come to code the ECU which arrived the next day!
He is a star and needs to move up north fast, he is one of the only guys who's input I trust :-)
No probs mate, I've heard its grim op north :grin: :laugh:
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Cracking work...again :grin:
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good work mate, I'd lose interest about half way lol :laugh:
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Good find with the replacement lump. Superb work as usual. :cool:
I imagine your Dad is proper stoked and I'm sure he'll love the loud pedal even more after a cheeky remap!
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Very cool!!
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Cheers guys :-)
The dad is properly over the moon with it haha, he says he can't believe how quick it is compaired to that nasty 2.0 8v
It does drive really well i must admit
He has now gone and bought a anniversary gearknob haha.. said he wanted one with 6 speed markings on it (the car already has full factory leathers etc so it will look pretty good)
Spoke to nick (Carbon) yesterday about mapping it, will most likely bob over to his house in Huddersfield soon :smiley:
Gotta keep it with Carbon after the fantastic work they have done to the Bad golf of mine :smiley:
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Skills :smiley:
At least you had a full on workshop; me and Dai did his in his garage at sub-zero temperatures :laugh: :laugh:
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mate iv been doing the caddy in the outside cold temp and its not nice!! :grin:
did a Clutch swap on a MK4 GTI the other nite and it was minus 6 and all we had was iPhone torches and some other crap lighting haha.. we didn't finish it till near midnight then bens car decided to bust a coolant hose LOL!!
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did a Clutch swap on a MK4 GTI the other nite and it was minus 6.. we didn't finish it till near midnight then bens car decided to bust a coolant hose LOL!!
Was it difficult? I've got to do that soon with just a Halfords tool set and some axle stands!
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did a Clutch swap on a MK4 GTI the other nite and it was minus 6.. we didn't finish it till near midnight then bens car decided to bust a coolant hose LOL!!
Was it difficult? I've got to do that soon with just a Halfords tool set and some axle stands!
na its pretty easy mate, major pain in the ass to get the box out of the car and even harder to get it back in, not much space. make sure theirs a few of you mate.. 2 people to hold/jiggle the box back into place and the other to get a bolt in !
very faffy job, was not ideal doing it in the dark and freezing temperatures!!
i did the one on my dads engine while it was on the engine crane before it went in the car and it was just pure bliss haha :grin:
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Does the starter motor need to come out to get access?
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yea it does theirs 2 bolts that hold it in, also have to remove gear linkage off the box, remove both driveshafts from the box and then you have around 6 or so bolts that hold the box to the block, these all have to come out obviously (might be more than 6 or less can't remember but you get the idea)
we also removed the air box too
you will need size 17, 18 and 13mm sockets
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Every cloud and all that, the starter motor needs stripping greasing and putting back together, least I can tackle two jobs at once!
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Top work as said it looks like a factory 1.8T :cool: :cool: :cool:
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Cheers Rich mate :cool:
Bob, its a fiddle but nothing you won't be able to do, its just getting box back into place tests the real pain in the ass part LOL
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Most of these jobs aren't overly difficult if you have the tools and time.
Brad, you've got too much time on your hands :grin:
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LOL i seriously don't have enough time in the day mate.. i never stop!! work, cars, DJ work, lack of sleep. girls... such a hard life i live haha! :laugh:
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LOL i seriously don't have enough time in the day mate.. i never stop!! work, cars, DJ work, lack of sleep. girls... such a hard life i live haha! :laugh:
It's either work or karate, so time is very limited.
I wish i had some time to do an engine conversion, i've got all the gear here :sad:
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I thought 3 days was good but 2 days, bloody show off lol :cool: