Mk2 1985 8v GTi - AGU 1.8t 20v conversion - COP + k04 upgrade - Kdfi (Megasquirt)

Hi there, have been reading a while now and thought it would be nice to show you my project.

Also a nice place where I can add pictures of the progress and any questions / problems I may have.

The car is mine (or my wife's) over 10 year now, and last 3 years been dismantled in my garage.
First I built a LPG injected 16v KR engine, but with new tax regulations and some problems in the KR I decided to sell the KR engines and go a step further. (I wanted a turbo anyway)

I bought myself a Skoda Octavia 1U with a AGU engine, and currently I am pulling the engine apart to get it upgraded.
Also I bought a used k04 turbo with manifold from a S3, this will spice the AGU a little bit more.

FOund good info about the motor supports here on the forum wwhich I have bought now on ebay.
Also today I bought 3 out of 4 lines from and to the turbo because I see the old ones are not gonna fit.
Only the coolant return is missing, but maybe I can convert the old one to fit.

I will add some pictures when I get them uploaded.

 

That sounds like a great project!!!

Do you have any photos of the car?

 

This is my Golf:


Here's the KR engine I've built.



The 'Donor' vehicle in better days


Started dismantling:



Hung it on the hoist for a better worling position. (yes i'm using chains now instead)


Here is where it needs to be put:


Allready bought a Sprinter intercooler and trial fitted it.


Here's the k04 i've sourced:


First trial yesterday, do I need to bend the coolant lines for the heater?


Here you can see that the original k03 lines will never fit...


So far the progress at the moment.

Still need to source some more parts like a trackslag downpipe but i still haven't decided 2,5" or 3" version.

 

Post is waiting for approval now.....

 

Extra details, I allready have my loom 99% finished for the engine.

I built the 16v using KDFi which is similar to a Megasquirt but prefabricated.

Only need to add the bits that control the boost.
I was even running on COP so all that is ready.

 

Post approved

 

Thanks !

Btw, I'm from the Netherlands.

 

Yup 1.8t is the light and the way

 

Welcome to Club GTI so English is your second language?

It looks a bit 'Back to the Future' with the stuff on the roof!! lol

 

"First trial yesterday, do I need to bend the coolant lines for the heater?"

Do you mean the metal water pipe? I sourced a BAM (k04'ed engine) water pipe for mine - cleared everything fine.

 

OK, that's one more thing to add to list with parts to look for.
Or is it a cheap part, than I will order a new one.
But maybe it could easily be bent out of the way, I have not seen any discussion obout this pipe before?

@1990 , I live near the German border so my German is good also.
(Also handy for VW parts which are much cheaper there, I also have a German delivery adress for my Ebay.de orders ;o)

 

i just eased mine out of the way...... cheaper :-)

 

I'll try that first too, can throw it away if it doesn't work.
any pictures on how you did it?

no problems with other lines which are running there like the cables from the gearbox?

 

Yeah,just bend it down,I had to do mine too,same with the oil return to the sump,bend it towards the block and gently trim the inside of the mk2 engine mounting bracket. Go for the 3" trackslag pipe if you can, its worth it for the flames alone but it does help with the EGT's as the k04 runs very hot as it is,I get a pop on every gear change with it,sounds good but not loud :-)

 

I now see that engines with the k04 engine have a secondary waterpump?
This type of pump was also on my VR5 passat which is of course also a temperature trouble engine.

Do I need one on my golf too? Maybe I could run it using a 'turbo-timer' device from ebay to cool the turbo after driving?

 

The fan after run doesn't run for long enough.

A mate has a delay off timer to run his. Like this.

http://www.polevolt.co.uk/acatalog/info_74205.html

 

Well on my mk3 it must have a high threshold. Runs for about a min.