GTII 16v Conversion

[Funky Diver]

that's a TIDY engine you have there mate... and can I borrow your engine hoist? I promise to only do a LITTLE bit of landscaping whilst I'm on...

[Cookie-101]

Anyone know where to get a new crankshaft pulley bolt from. Need one ASAP.

[snathe]

Good little project this
Fitting my KR over the next week or so, but i've gone down the twin 40 carb route instead of injection. Keeps it all nice and simple that way lol...
Keep up the good work, and more pics to give me motivation!!!

[Cookie-101]

Right, got everything ready to drop the block and gearbox in now. Im not putting the head on yet as it will be easier to drop in without it, also want to wait until i've got the exhaust manifold (which i still need to order). Here's a pic of the block mounted up to the gearbox:



I'm using the clutch that was on the 8v, seems to look pretty new so im not to worried about it, its got plenty of life left in it yet.

Also my megasquirt ecu turned up today so here's a pic of that too:



I'll try and get some pics later when the block and gearbox are in (depending on how much light is left in the day).

ps, i really need a crankshaft pulley bolt if anyone knows where to get one.

[Funky Diver]

Oddly enogh, I need one too... but I'm not in a rush...

Tried VW dealer?

[Cookie-101]

Not tried the dealers yet, will have to get on it.


and as promised:

[Funky Diver]

you kinda forget how far over to the left the engine sits...

[Cookie-101]

Just a quick update.

I noticed the intercam timing was slightly off so I took them out to find that the previous owner of the engine had stripped some of the studs for the bearing caps. A few phone calls later a new set has been ordered as well as the nuts (also got a crankshaft pulley bolt), but can't collect them till tuesday due to the bank holidays etc. So i have taken them all out and fitted the head and test fitted the manifold. Here are some pics:

Nice new head gasket:



Head fitted, minus camshafts:



Test fit of intake manifold:



Also got to make a spacer for the water pump pulley, as the crankshaft sprocket on the ACE is about 6mm wider than the 8v's one.

Got to sort out the megasquirt and the plumbing now.

[Cookie-101]

got the cams back in now so the head is on for the last time.

Got my exhaust manifold, just got to figure out how to connect it to my jetex system and sort out the problems I know im going to have with the steering boot.



Been trying to sort some clearance issues with the distributor, master cyclinder and the intake pipe, thought i had it then realised the expansion tank was out the car going to go for a 90 degree bend instead of a 45. Mounting the distributor upside down sorted the clash from the m/c.





Does anybody know how to wire up Megasquirt ECU to the hall sender, do i still need the ignition module thinger in the scuttle?

Hopefully be fireing it up this weekend or next.

[Cookie-101]

Another update, this is taking much longer than I expected as getting hold of some of the littler parts has been a nightmare.

Right so i got a 90 degree bend to sort out the clearance issue and then got a standard cap on the brake fluid reservoir. Its snug but it just fits:



Also got the majority of the wiring done. Does anybody know where to get a good 12v source from thats on when the ignition is on and when the starter is going?

Having issues with the hot tunning manifold i got off ebay. I'll say this to anyone doing this coversion, dont buy this manifold it doesnt fit:



Major clearance issues between it and the steering boot. Luckily they said i can send it back and get a refund.

Going to try and go for a dubpower one which comes with a flexi section to link up to the exhaust system. I've read that they were designed for RHD cars:





Im also struggeling to get hold of the alternator brackets.

[Rusty dan]

Looking good mate and loving the red/silver contrast!
With the engine out I would have taken opportunity to clean the bay up and bring back the deep red colour.

[Rusty dan]

The manifold does fit as I have one but you need to lose the dust boot on the steering uj. Its just a dust boot and does not effect an MOT.
I am running mine without.

In hindsight I would have taken the same route as Monza Jake and got a Supersprint one. More money but a better fit.

[Cookie-101]

The manifold does fit as I have one but you need to lose the dust boot on the steering uj. Its just a dust boot and does not effect an MOT.
I am running mine without.

In hindsight I would have taken the same route as Monza Jake and got a Supersprint one. More money but a better fit.

I thought that the heat from the manifold would melt the grease in the joint causing it to seize. I think it happened to someone on the mk1 golf owners club forum or club gti. How did you mount the manifold up to the your exhaust, did you get a custom piece made? Im left with about a metre gap between my jetex system and the manifold.

[Rusty dan]

The manifold does fit as I have one but you need to lose the dust boot on the steering uj. Its just a dust boot and does not effect an MOT.
I am running mine without.

In hindsight I would have taken the same route as Monza Jake and got a Supersprint one. More money but a better fit.

I thought that the heat from the manifold would melt the grease in the joint causing it to seize. I think it happened to someone on the mk1 golf owners club forum or club gti. How did you mount the manifold up to the your exhaust, did you get a custom piece made? Im left with about a metre gap between my jetex system and the manifold.

I think all you will require is something like this to join the manifold to the existing exhaust. (assuming you are 2.5", (they do other sizes))
http://www.merlinmotorsport.co.uk/p1538 ... _info.html
http://www.merlinmotorsport.co.uk/p1543 ... _info.html

Hope this helps mate. Very jelous of you inlet manifold, the car is screaming ffor a s/charger

My exhaust is 2.5" all the way...
I welded a short section of tube to the seperate flange you get in the kit that bolts up to the flange on the manifold.
Then got a flexi pipe to take the strains aand hopefully prevent the manifold cracking and attached to the short tube.
Sorted another length of tube and then put on the centre silencer (which does not do anything to make it silent lol)
Then put in a bend and a side exit.

I made the exhaust myself and got the bits needed from merlin motorsport who I thought had very reasonable prices

(The pic below was a mock up and not the final design)

[Brunty]

I thought that the heat from the manifold would melt the grease in the joint causing it to seize.

That joint isn't greased. It could well get stiff if unused and rusty though. My old supersprint 4 branch cooked the rubber boot and I got no problems.

I'll be having a shot a supercharging my ACE with scirocco 16v inlet manifold :)