ABF into CE1 - She fliessss :D

[fishnchipsx2]

As promised...


I haven't done much since the last update, but I just took a sh*tload of pics, so here they are. 

"Before" shot of the engine bay...

..."After" shot will come later if I actually bother to clean it 

Bagz sold me his 8v 4-branch today (even tho he needs it to replace his cracked manifold  ), this is it placed on top of the diesel downpipe.


Need to cut off the flange, get Mr Coltech the welder to bend 2 pipes and weld on a plasma-cut 16v flange.  Works out cheaper than buying a 16v conversion 4-branch, and it will actually fit without fouling the steering rack (hopefully )


It also has a gash bit of 2.5" flexi welded onto the end [xx(], think I'll cut it off and get a proper braided flexi welded on.


Also needs a reducer to the standard 1.5" exhaust.  Restrictive I know, but it'll do for now!


Manifold came with heat-wrap too 


Drained diesel out of tank, took it off and rinsed it out with petrol, then put it back on:


Put a brand spanking new mk2 16v clutch on the ABF to match the KR gearbox I'll be using:


Bolted up the mk1 driver's side engine mount.  Trimmed the lower cambelt cover so it would fit, will probably need a bit more taking off to clear the body mount:


Metal oil cap FTW:


Found that the fitting for feed to the fuel rail has been snapped, found part no. on Vagcat so will find out if the Stealers have any on Monday:


Although there is a blocked-off nipple further down the rail, maybe I could use that if needed...? ...hopefully won't need to consider that option tho!


This is the diesel sump, Animal (previous owner of the truck) put a nice hardcore plate on it, so I'll be using it instead of the ABF's pussy ali sump.  (Oh and there's Muttley making another appearance, cheeky!)


That's all for now, I plan to bolt the engine in tomorrow 

[fishnchipsx2]

Been thinking a bit harder about the fuel pump situation.  I've come to the conclusion that seeing as I don't have a lift pump, I SHOULD use the accumulator? 

[danny_p]

accumilator has no purpose with digi, but you do need lift pump

[Diamond Hell]

Pumps either push or pull, not both.

The lift pump pulls, the pressure pump, pushes.  You need both.

Don't ask the push pump to pull, it'll expire rather fast.

[fishnchipsx2]

Still haven't got my head round this fuel pump thing... in my mind, the K-Jet pump was designed to be fed by gravity straight from the tank as in all mk1 gti's, so I don't see the problem here.  However, the words of DH and DannyP tend to be wise words, so I will buy a lift pump asap 

More progress today, I'll post when the photof**ket upload finishes...   

[fishnchipsx2]

Started this morning with this:


Removed ali sump, fitted plated steel sump with new gasket:


Had a few mates coming and going to lend helping hands throughout the day, mk2 KR gearbox going on here: (Also set up a sunshade, today was HOT! 


Engine going in:







The tensioner on the ridiculously large ABF alternator bracket fouled the chassis leg.  Apparently a 2.0 8v alternator setup will fit, but I opted for the "if there's no space, make some" method:



Bagz hard at work:



A reasonably large dent was made, protected from rust with spray-on underseal.  It's never going to be a shiny show-bay!



Then I jacked up the front for better access to mounts etc:





Doing rear gearbox mount here I think, putting the carpet down on the gravel drive was a goooood idea, saves dropped nuts and bolts from getting buried too:







Front mount has too much space, although this is common on Mk1s.  I pikeyed a spacer plate a mate made up out of thick ali for his mk1, which he no longer uses as the gap closed up when we raised his engine 2 inches a couple of weeks ago.



But the important thing is, she's in!



Put the upper inlet manifold on right away, don't want any rogue nuts falling down the ports!





Got a list of bits and bobs to get tomorrow like fuel hose, clips, dizzy cap+rotor arm, brake fluid resevoir (mate dropped the engine onto the old one! ), oil filter, alternator belt etc.  Then it's time to get stuck in with the wiring 

[danny_p]

you may get away with gravity feeding the pump, it worked for some audi's and t25'.

i've had problems with gravity fed injection pumps before tho caused menay hours of headbanging on the mg

[rubjonny]

you might get away without the lift pump on this tank as the outlet is at the bottom, mk1 GTIs had the outlet on the bottom of the tank and this was plumbed in direct to the main pump.  However, they also had a swirl pot built into the tank to prevent fuel starvation, if the diesel tank doesnt have one you may suffer from fuel starvation as the fuel sloshes about in the tank.  If you remove the level sender from your tank and shine a torch in you should see the swirl pot sat in there if fitted, its like a round pot sat in the lowest part of the tank, the oputlet on the base of the tank is fed from this pot. 

If you can just see the tank is empty and the outlets are just sat in the side of the tank, you need a lift pump. the later cabrio and scirocco used a lift pump, this didn't have a swirl pot. to prevent fuel starvation issues there was a plastic reservoir fitted under the car in front of the main pump.  The MK2 GTI doesn't have a swirl pot either, the main pump is sat inside a plastic tank which performs the same job as the separate plastic tank on the MK1 cabrio/scirocco.
you can get the lift pump and tank from MK3 Polos as well as later cabrio/scirocco. Any MK3 Polo will do as they're all fuel injected (think Polo G40 shape)  Also they have a handy braket which holds the reservoir, main pump and fuel filter under the car in a line which may be useful to you.
The main pump setup from a GT or G40 will be fine on the ABF engine as well, but you already have a k-jet pump so I would use that. You can hack the ruber pipe off the banjo bolt on the end of the pump and pop on your rubber pipe to there, or alternativly you can get new banjo fittings designed for push fit rubber fuel injection hose on ebay.

as above either way you go about it, you dont need the accumulator its only needed on k-jet models.

edit: oh and MK2 lift pumps wont fit a MK1 tank, but I'm not sure what the fitting is like on a caddy tank, can you get pics?

[fishnchipsx2]

Good stuff, that makes more sense to me now.    I'll be down the scrappies sometime this week hopefully, should be able to find one then, plus some vauxhall calipers which are supposed to bolt right up to mk1s with some shoulder bolts I already have.

I plan to use the calipers with 280mm 5-stud Mk3 discs.   However, I'm not actually sure this is going to work: I've only seen this done with 4-stud discs, and I believe they have a slightly different offset to 5-stud discs?     I think that what I need is 'narrow-track 5-stud discs'... maybe off some sort of Seat? Would be nice to buy some discs off the shelf and not have to re-drill G60 discs.

[rubjonny]

howe have you converted it to 5 stud chap? cant see any reference in this thread?