This is where it begins fully
The engine is in, well it was it's back out now
Slight issue with the sump. I have a solution though I hope
Just changed the gear linkage from rod change to cable change and started to swap the pedal box over to the hydraulic version from a Passat GT to match the gearbox which has altered ratios.
So far so good couple of things are a pain to figure out but nobody said this was going to be plug and play and I do like a good challenge :lol:
09 feb 09 update
So to anyone thinking of putting an AEB into a mk2 golf here are the gotcha's I've come across so far.
Exhaust manifold and turbo hit the rear engine mount, currently deciding whether to grind a bit off so it clears it or use a mk4 golf transverse turbo and exhaust manifold, or mount the audi turbo on the mk4 Golf exhaust manifold.
Sump is far too big, have a cunning plan using a 16v steel sump and oil pickup pipe, need to check it fits and make an oil return hole for the turbo.
The AEB uses a nipple for the coolant feed from the block to turbo and the AGU has a 14mm threaded Banjo bolt.
The alternator fouls the throttle body think the mount needs changing over
The inlet manifold hits the front panel so a transverse one is required to make it work, which means you need a transverse fuel rail to match.
The angled oil filter housing from the AEB interferes with the front engine mount so a different one has to be used, I have an AGU one but it really doesn't fit, totally different.
The Audi has a second fan that runs from the alternator belt which confuses the belt issue, I have a VR6 water pump pulley to try and get it right.
The routing of water pipes on the block doesn't match after putting an AGU inlet manifold on + a few other bits. I have a full set of coolant hoses from ..... An AGU engine to try and fasten up.
Auto box = new flywheel and clutch to mate to a transverse engine. I have a Passat GT one with a VR6 clutch which bolts up ok.
Going to try and get a couple of days at it this week and get the block built up and hopefully drop it into the bay one last time next week
16th March 09Bit of an update guys,
The engine is now in the bay, a mk4 golf turbo and manifold have been put on along with the mk4 coolant and oil lines to the turbo, 16v sump from a KR has been fitted and seems ok had to fit an oil return to it and hoping the driveshaft clears it
Finally found the oil cooler bracket I needed on a mk3 TDI and got a Mocal oil cooler kit for it to hopefully keep the temps down under the bonnet.
I have an ECU on it's way at the end of the month which is a new unknown unit but the spec list is pretty awesome such toys as progressive boost control, launch control, wideband support, traction control, switchable maps etc .
Radiator and intercooler pipework is next and hopefully my downpipe will arrive this week allowing me to get as much as possible plumbed in before the ECU arrives
Intercooler is from a new transit and seems to fit nicely behind the bumper so that should keep things nice and cool.
Elsecar in less than 4 weeks OMFG!
3rd April 09More work done recently, lots of messing about trying to get the coolant pipes to run properly and oil pipes for the turbo in, these are now sorted bar the shouting and my new intercooler arrived along with some silicone hoses, so I am now onto running and planning boost hoses and mounting the intercooler.
I had to put the grill on to check the centre spots still fit with the intercooler in place which has made me want to finish it soon.
16v Sump is now fitted and also has the oil return in. need to make a bracket to hold the alternator in a different position so it clears the throttle body.
Got some twin pot 280mm S2 brake calipers and carriers so building those up and just hoping they will clear the inside of my wheels
Got a bracket missing from the gearbox, need to go hunting around scrapyards.
ECU is delayed so not going to make Elsecar hoping to have it ready for Big Bang at the end of April.
25/04/09Spent most of today in my garage and got a fair bit done. Bit of an update and some pics
I have got the intercooler and rad mounted up and plumbed in,
Intake pipe to turbo and outlet pipe are in place,
Coolant pipes are done bar a few jubilee clips,
Wiring loom is plugged in and nicely grommeted into the raintray ready for splicing into the ECU when it arrives.
Gearbox and rocker cover/inlet manifold are now black again,
New wheels are on the way to fit over my new shiny S2 brakes,
Things still to do.
ECU wiring and headlights horn etc
Not found a gearbox shift lever thingy yet, the hunt continues.
Need to sort the vacuum system out and plumb in the dump valve etc.
Some fuel lines to make up,
Brake lines to sort out,
Clutch to fill and bleed,
Brake hubs need rebuilding with new flange and bearings.
Calipers need fitting to rebuilt hubs,
Driveshafts fitting to gearbox and hub,
Fuel putting in as it was nearly empty,
Dash to put back in,
carpets and seats to go back in,
new wheels on,
MoT and Tax
DRIVE!
Put the front back on, looks like a golf again
