engine conversion

[alicarv96]

I am considering doing a 1.8 20v turbo conversion on my mk2 and i was wondering what is needed to do the conversion? and what difficulties have people met when doing the conversion?
cheers
Ali

[the edmundator]

Look in the projects section, there are a couple in there.

[bengould]

Engine - Any transverse 20vt. Longitudinal can be done but needs a lot parts swapping with those off a transverse engine.
Gearbox - 020 will do if your engine is stock, any mods and it is worth going to 02A or 02J.

Gear shifter mech - If you change the gearbox for an 02A/J you will need the cables and shifter that match the gearbox type.

ECU - Either standard or aftermarket, depends what power you want long term. If you stay standard you will need someone to code out the immobiliser.
Loom - Depends a lot on the ECU Choice. Standard ECU you can convert the loom yourself, or pay someone to do it for you. Aftermarket ECU Will need a custom loom.
Rev Counter - If your dash has one, you'll need a tacho converter to give it the right signal.

Throttle pedal - Early cable throttle engines you can keep a standard pedal. Newer Drive by wire engines you will need the Drive By Wire setup.
Clutch pedal - Depending on your gearbox some are cable some are hydraulic. If you get a hydraulic gearbox you either need a hydraulic master cylinder or convert the box to cable change (The bits required are VERY rare, only found on low spec seats AFAIK)

Engine/gearbox mounts - Can be bought off the shelf or made yourself. Much cheaper to make them yourself but depends how much you trust your welding.
Exhaust - Minimum 2" system, will require a custom downpipe, these can be bought ready made from several places, or if you're getting a stainless system made for the car the company that does it should be able to make something suitable. Ideally 3" downpipe into 2/2.5" system. Don't worry too much about noise using a large bore exhaust, the turbo quietens it down a LOT more than you would expect. I use the same exhaust I had made for my 8v engine and it is a lot quieter attached a 20vt.

Driveshafts - Can stay standard unless going for crazy power, 100mm CV joints recommended (Needed for 02A/J box)

Intercooler - Early Mercedes sprinter fits (Just) as a cheap option, Many other options available either designed for the job or just something out of a car that happens to fit in the space you have.

Air intake hoses - Get a load of pipes and joins/elbows and make it fit where you have room.

Air filter - Any cone filter to suit the size of your MAF/Intake hoses.

Radiator - Can stay standard, the wider injection radiator is best. Or again many other custom options.

Water hoses - Get as many different hoses as you can and find some way of joining it all together - Many trips to a scrap yard may be needed for this bit. Depends a bit on the radiator you use.


Brakes - You can stay standard IF your brakes are in good condition, set up PROPERLY and you are brave/stupid. Rear discs are not needed, just good fronts, they do most of the work anyway.

Tyres - Cheap tyres will NOT grip. Wheelspin when accelerating at 50-70mph in 3rd in the wet is not fun.


Probably more I've forgotten, you will get teething problems, but it is well worth it once you are all done and running.

Ben

[essextom]

I've just embarked on my 20vt conversion.
Price wise: mounts £100 ish from retrofication (google it) they do a hyd clutch mounting bracket thing for £40. Found a bloke up Scotland way (eBay) who is going to splice the looms and de code immobiliser and I think a taco thing for about £300. Downpipe is roughly £180. I've bought a ko3s turbo for £120, prob worth doing whilst engine is out. You will need a 1.8 16v kr cam belt tensioner £15 from europarts. Honda S2000 standard air filter is good and cheap £15. You'll also need engine mount bushes about £15 each. That's all I've sorted so far.

[connorj19]

I've just embarked on my 20vt conversion.
Price wise: mounts £100 ish from retrofication (google it) they do a hyd clutch mounting bracket thing for £40. Found a bloke up Scotland way (eBay) who is going to splice the looms and de code immobiliser and I think a taco thing for about £300. Downpipe is roughly £180. I've bought a ko3s turbo for £120, prob worth doing whilst engine is out. You will need a 1.8 16v kr cam belt tensioner £15 from europarts. Honda S2000 standard air filter is good and cheap £15. You'll also need engine mount bushes about £15 each. That's all I've sorted so far.

Same here very early days, what you doing fuel pump wise? My roc has a carb as standard so I've bought a sender unit with pump off Ben on here. Just not sure what to use for main pump. I'm going down same route having sombody sort wiring & using retrofacation mounts. I've ordered the 280mm brake adapters from them so will see what epytec quality is like. Probably gunna use qpeng downpipe for simplicity. Apart from that it's pretty plain sailing. This is my first engine conversion and liking it so far

[Nate]

Wheelspin when accelerating at 50-70mph in 3rd in the wet is not fun.

Yes it is!

[connorj19]

Wheelspin when accelerating at 50-70mph in 3rd in the wet is not fun.

Yes it is!

Sounds like the Rocco would Beifit from Quattro drive system, always wanted to build something that tries to kill you when you get being the wheel. Can't wait till mind is finished

[connorj19]

Would these be suitable to go in the spare wheel well ? Swirl pot n main pump in one unit ?