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    1. 05-27-2006 04:59 AM #1
      Hey guys,
      I have begun the conversion...
      I am taking out a 2.0L 8v multi-point injection 85kw motor, and installing a 2.0L 16v ABF multi-point injection 110kw motor and a stronger gearbox...
      First of all, my reasons for starting the project

      It's known as a crumble box or 020
      Suprisingly, it still drives!
      And goes clunk clunk...
      So, i bought this...

      and the important DUAL CAMSHAFTS!

      ANd the work begins...

      (and the crate it came in....)

    2. 05-27-2006 06:02 AM #2
      It's really good to see a post like this in the Australian forum. I see heaps of this in the mk2 forum and glad to see a bit is going on closer to home. Keep on updating!

    3. 05-27-2006 06:13 AM #3
      I am running this thread in a few areas now...
      Yeah, its from an early EURO mk3 GTI and has digi 3.1...if it did have digi 3.2 i'd have to have the key and transponder thing, or go aftermarket...motec..hehehe...
      Otherwise, Carl provided a full gasket kit with it, which means that when i do the head gasket, i'll get the head crack tested and then ported and polished...
      But because that will happen before it gets running, then i won't be able to do a before and after power test...
      Other mods will be the BMC CDA airbox i already have. Catch can to remove the PCV oil going into the intake, i hate that build up!! And the exhaust will need to be redone as the baffles in my DTM style muffler are broken...
      And when it is running, i will want new cams...
      But the question is....Would there be any performance gains in getting new valves and valve springs while i do the head??

    4. Banned
      Join Date
      Aug 31st, 2005
      05-27-2006 06:30 AM #4
      Just rev the bananas out of it. If you get some valve bounce then replace your springs. I am assuming that you have not stripped the old engine yet.
      If you have and you are getting the cylinder head reconditioned, then I would be putting new valves, springs and camshafts.

      Modified by ABrz... at 3:31 AM 5-27-2006

    5. Member mdt's Avatar
      Join Date
      Nov 21st, 2001
      05-27-2006 09:00 AM #5
      Good stuff Sean. [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    6. 05-27-2006 11:40 AM #6
      I went back this evening to do some more stuff...
      Only removed the repaired aluminium sump on the 16v, and managed to crack the sump plug. It was on really really tight!!! So, instead of taking the sump off my 8v, i can still use this one...
      And i took the old 020 gearbox off the 8v motor aswell and i found another big hole in the bellhousing and the broken rivets...
      I tried to pry apart the gearbox casing to see more, but i gave up...
      I will source another bell housing half and repair the rivets to bolts...
      But if that happens, then that stuff will probably go in a mk1 or something...NEXT PROJECT..hahaha

      The clutch is rooted on the 16v, so i'll need a new one of those...
      And the spark plug leads have a gash in one of them, so i'll need to get some new leads too..

    7. Member Gigitt's Avatar
      Join Date
      May 25th, 2004
      2011 Jetta 125TDI, 1996 Mk3 TDI Squid
      05-27-2006 01:26 PM #7
      Damn... someone say Sump Damage!
      Keep it up.
      I looking forward to More Pics and reading all the tidbits of the project you can spare time to type...
      [IMG]http://*****************.com/smile/emthup.gif[/IMG] [IMG]http://*****************.com/smile/emthup.gif[/IMG] [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    8. 05-27-2006 07:18 PM #8
      Nice conversion mate.
      You can use your 8v Sump, geez that gearbox looks rooted. definitely good for spares.
      Keep the updates coming.

    9. 05-28-2006 07:22 AM #9
      It's effectively day three now, being sunday night, and considering i started friday night...
      Today i did some removal and installation, as well as checks and inspections...
      One of the leads that came in the bundle of goodies has a gash on it, so i will get new leads soon...
      I also lound gashes in what appears to be a knock sensor that was bolted to the block... PN# 037 905 377A
      Although, i looked on my 8v block and it has something with a different connector, but the same PN#.
      Also, considering its a 02A gearbox, i discovered i need the front and rear mounting brackets from a VR6 or similar...
      Haven't worked out a source yet...
      I also spotted my exhaust is squashed, I'm pretty puzzled as to how it happened, I wonder if it would affect performance at all...???
      I removed the gear change linkage assembly and installed the gear change cable assembly...
      It was very easy to do and only required dropping the exhaust out of the way and bending (yes bending, hahaha) the heat shield out of the way. The assembly then just came out easily, and went in even better!!
      Otherwise, Matt and I removed the head off the block. (I've never done it before)
      Matt says there is nothing wrong with the cylinders and the pistons look fine. There is still the cross-hatching on the cylinder walls and only faint vertical lines...
      The head and flywheel have now been sent off to get tested and machined if need be... I'll get a quote on that port and polish too!
      During the week, I may or may not be doing work on it...
      But i will definitely be chasing down parts during business hours...
      And the photos...

      The squashed down pipe and cable change gear now in place...

      The cable..

      It looks clean!

      COUNT THEM....16 Valves!!

      And my friend Matt...

      And me "gettin' jiggy wit it..."

      Modified by zero thrust angle at 4:25 AM 5-28-2006

    10. 05-28-2006 07:34 PM #10
      Heya, whats the year stamp on the front of your block?

    11. 05-28-2006 08:12 PM #11
      good project !
      I hate finding out little things that turn out being major PITA jobs like that mount point.
      Hope it all goes well.
      BTW - how can you get any work done with that bird sitting around the workshop?

    12. Member VDUB2C's Avatar
      Join Date
      Dec 18th, 2002
      '10 Golf GTD
      05-28-2006 08:27 PM #12
      Nice one dude [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      Can't wait to see the completed product.
      next project: Supercharge the farker
      VW MKVI Golf GTD - Black | Sunroof | MDi | Manual | RNS-510 | Hyper Silver GTC CX 18" | ChipExpress

    13. Member Gigitt's Avatar
      Join Date
      May 25th, 2004
      2011 Jetta 125TDI, 1996 Mk3 TDI Squid
      05-28-2006 09:08 PM #14
      Quote, originally posted by zero thrust angle »
      NO NO!

      Bwahahaha.... DO IT!!!!!!!!

    14. 05-28-2006 10:06 PM #15
      thanks i'll put that in my wish list.

    15. 05-28-2006 10:17 PM #16
      Quote, originally posted by zero thrust angle »

      2 things:
      1) She's cute. More pics!
      2) I love the turbo conversion idea. You can trust any turbo kit that includes a... "mit allen Dichtungen und Hosenrohranschlussflansch"

    16. 05-29-2006 05:48 AM #17
      shes really a hermaphrodite guys...
      hi sean! i couldnt remember my log in so i got a new one!

    17. Member TMK-001's Avatar
      Join Date
      Apr 14th, 2005
      Mt Gambier/Portland/Geelong/OnMyBike
      05-29-2006 06:24 AM #18
      Awesome dude - when we spoke last this was all a bit of a pipe dream then BAM its all go!
      Is that Golf4's golf there? I take it that is Slow POS

    18. 05-29-2006 09:24 AM #19
      yeah thats me lol. no point hiding its slow lol

    19. Member TMK-001's Avatar
      Join Date
      Apr 14th, 2005
      Mt Gambier/Portland/Geelong/OnMyBike
      05-29-2006 09:25 AM #20
      Engine upgrade!?!

    20. 06-03-2006 10:46 PM #21
      Hey again!
      So far this weekend I finished off swapping over the wiring loom, the ecu, and plugging it all into the fusebox...
      Otherwise, we pulled off the bearing caps, and have decided to replace those, and I'm unsure if i should replace the piston rings at this point...
      I also recieved my mounts from Golf Loon, thank you very much! Very speedy deilivery! Although, i found one of the mounts i bought, i already had...ooops...
      So, this is me getting my head around the wiring...

      The loom...

      Half way...

      Where it had to go...

      The wishing well, first i dropped a clip, then some rubbish, then some coins for good luck...

      Modified by zero thrust angle at 7:49 PM 6-3-2006

    21. Senior Member
      Join Date
      Dec 19th, 2004
      06-03-2006 10:59 PM #22
      [QUOTE=zero thrust angle]So, this is me getting my head around the wiring...

      Hey Sean, you sure you want to do Commerce instead of electrical engineering? You seemed to be good at it. Lol.
      Quote Originally Posted by Jim Bookie View Post
      gt2 is a luxury car, yes.

    22. Banned
      Join Date
      Aug 31st, 2005
      06-04-2006 08:25 AM #23
      You may as well do a full rebuild on the engine, crikey with that much effort already involved - may as well do a perfect job.

    23. 06-04-2006 08:31 AM #24
      If you have a look at the steering universal boot you can see that its frayed , common problem on all 4 cylinder mk3's and extractor fitted mk3 vr6's . Hope you'll be changing that part [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    24. 06-04-2006 08:35 AM #25
      Yer, its no biggie to change now that there is nothing in the engine bay!
      I also have to give the whole bay a clean, and tidy up of the wiring...
      Does all old vw wiring wrap fall apart like that??

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