Golf mk2 GTI 8v to 1.8t AGU, mk4 dash and wiring Updated 13/02/11

Great job mate.
Just found this thread and theres loads of useful info.
Every time i see a thread like this it an inspiration to do my own.....one day.

 

Read This Thread Twice Now Done A Really Good Job And Great Thread... Im Think Of Doing The Same But With A 1.9tdi Pd Block.. Thread Is Going To Be So Usefull


Thanks

 

Hi All! Remember me??? I am shamefaced to see that my last post was in 2009!! The car is on the road but the project is very much still ongoing :-)

Here are the things I've done since my last update...

I had some major running issues with the car. It would accellerate nice and fast in first and second gear but then would lose power and/or stutter. I figured it was something to do with the sensors or air getting in after the MAF...so I changed the N75 valve, the MAF, vacuum hoses, cam shaft sensor, cleaned the throttle body, checked injectors...etc etc etc...nothing resolved it so I thought it was the turbo...

...good chance to upgrade to KO3s :-)



Turbo removed




cracks inside




KO3s




I thought I'd fit a new exhaust manifold while I was at it...the old one had a few cracks inside




This STILL didn't fix the problem, so I upgraded all the air hoses for SFS silicon hoses...with proper hose joiners and rally spec clips...the car looked bad ass!




But still the car was running like crap...last port of call was to change the exhaust. I figured that the airflow was being restricted going from the turbo down to the Mk2 silencers and then the back box so I got a QPENG downpipe then had Powerflow make me the rest...


2.5" with a sports cat and silencer






Night shot of my dash in full glow...




Ok...SOOO....after all that money spent on sensors, turbo, hoses, clips, manifolds etc...I still had the problem with the engine running like crap. VAG-COM wasn't showing any errors which was frustrating.

My last resort was to get the car booked in at AMD Technik in Essex. These guys had a good reputation for tuning and diagnostics, so figured I'd give them a try....and get a remap while I'm at it.

The guys were true to their reputation! They fixed my problem AND remapped it to 210 BHP

It was the first time I drove the car without it spluttering on me and WOW! I had a grin from ear to ear for about a month after I picked it up! The problem was the fuel pump I put in...it wasn't working properly and therefore was starving the engine on higher revs.

AMD were fantastic...I can't recommend them enough!

 

Now that the engine was running nicely, I had time to finish off some other jobs.

Those hideous cream sun visor monitors were swapped out with larger black ones



It was time to cover the doors with the sound proof material, which would also act as the waterproof membrane...









With the interior almost complete, I had one last major job to do. I'd been kicking myself for not installing a 6 speed

gearbox when the car was apart and as the Mk3 gearbox was making a whirring sound, it was time to upgrade the gearbox

It was time to install the 6 speed 02s gearbox from a Golf mk5 2.0l FSI (NOT TFSI!!!). Took me weeks to get hold of it but

finally it's mine...

The 02s is on the right. The gearbox on the left is the 5 speed 02j from the mk4 golf.



The 02s has the same bell housing as the mk4's 02j. It is also the only 6 speed gearbox that can fit straight into the mk2

using the top gearbox mount from the mk3's 02A gearbox.The rear mount will need a bracket to fit properly.

The only problem with the 02s is that is has no speedo mechanism...



This is where the 02j comes into the picture as it has one...



So the plan is to strip the 02j and then get a gearbox specialist to put the 02j's bellhousing (with speedo) onto the 6 speed

02s




A Pic of the mk3 02A in the car...the winter was not kind to my GAZ shocks



02A out...



The 02s needs a bracket for the rear mount....I made it out of 6mm steel. It was vital to get the holes for the bolts spot

on.




Once those two holes were drilled and the bracket was in place, I had to measure out the 2 holes for the rear mount to screw

into..



Then create the thread for them...



and finally attach the mount...

 

And the gearbox is ready to go in...



For anyone doing this...it's almost impossible to find out which oil goes into the 02s. VW sell it but they don't know the

viscosity so here it is...




Next step was to solve one of the early issues I had...the gear stick. I'd fitted the mk3's cable shifter, however it was quite short and moved too far on gear changes...I kept turning the air conditioning on. Here's an earlier pic of how it was...



So...time to swap it out with a mk4 6 speed shifter.

To start with, the two rear fixing tabs have to go...





Also the bits circled need to be cut out and flattened, as they won't fit through the hole in the tunnel.



Quick stencil to work out where to drill the holes in the tunnel...



Holes drilled



Before the shifter can go in, there's a bracket on the underside of the tunnel that needs to be removed. This held in the old shifter. Some people drill the spot welds, but because I had a full powerflow exhaust, this was not possible. I had to cut/chisel/force the damned thing out

 

Great work mate, nice update and info on the upgrades.

 

Such a great build. Dont know how i missed this one.

Love the MK4 dash conversion, and the detail on the engine. Top build mate

 

Awesome build thread

 

Nice build!! Well photographed. I always forget to take photos.

 

Thank you very much guys

I didn't have a pic of the gear stick once it was finished, so here they are...(I took Scorian's advice about all the red on the dash, so used silver vinyl to cover the vents and central fascia)



Nowhere near the AC button when in first gear now



I saw this first aid kit going cheap in VW and knew a perfect spot for it...




I also treated 'blue' to some smoked crystal headlights...





The blue golf is a Syncro...it's a hint at my next project

 

hey goran, its ben from up the road just read through this lot and didnt realise u'd done quite so much lol, i know where ill be coming for my abf conversion in the coming weeks ! loving the car, now time to get the syncro done keep up the good work!!

ben

 

Like, lovely sleeper... Nice one.

And another project ready to start, good man!

 

Hey Ben! I guess you can see from the cars on my driveway what will be going into the Syncro

Give me a shout if you need help with your ABF conversion - I've got an engine crane I can bring up here if you haven't already got one.

There's still loads to do on this one....the project is by no means finished. I've still got the central locking wiring to do for the rear doors, need to tidy the engine bay, refurb the alloys and then get it resprayed inside out

Thanks for the comments guys. Any ideas on gadgets I could add will be appreciated...

 

hey oh yes should be a machine when thats done, you goin to leave the engine standard or?... haha thanx mate i shall let you know if i do

 

On which one? The red one has been remapped to 210bhp. The syncro will eventually be ~260 but not for a while...with the respray etc it'll take a long while to save up

Priority for now is to get everything in and working...then I'll worry about tidying up and making it pretty Time is the biggest problem at the moment...I'm looking forward to the summer, when the evenings are long enough to actually get stuff done. I miss my garage!

 

yeah i ment the syncro ah your telling me i cant even afford a cheap abf conversion! good news is that i now work for the vw breakers so if you need anything give me a shout! is the syncro at yours by the way haven't seen it lately? also i understand having no garage is a pain lol!

 

Conversions aren't cheap...I found the best thing to do is source a whole car for cheap...at least then you don't have to buy the parts separately and pay loads for them like I did with the red golf

OOh...are you working at Steven's? I do need a front driver's side '90 spec wheel arch if there are any going

The Syncro is at the back of the driveway - the engine was about to blow up (big end bearings were rattling and it was going through a litre of oil in about 20 mins) so I parked it up before it kicked the bucket. I've already stripped the interior out of it in prep for the project I'll get round to starting a separate thread for it when I get a spare evening.

There must be someone locally with a double garage they're not making use of....or a cheap unit we can rent out...

 

wow

great job

 

Hi really great build thread and a great job done too! just wondering what mounts did you use as im currently doing a 20v t conversion and confused on what mounts to use cheers.

 

Thanks

I've got some more updates to put up too so watch this space.

I used the mounts from a late mk3 GTI 16v (ABF engine I believe). The gearbox mount is from the mk3 and this same one fitted the 6 speed 02s gearbox. The mounts you use will depend on the gearbox you're fitting to the car.