Gti advice?

[tiki25]

HI,
Finally got my van up and running after sitting for two years! Runs ok but a bit lumpy and using a lot of water. Was thinking of getting a reconditioned lump but been told the 1.9 dg is not the greatest engine and also lacking in performance for my liking. Have been offered a 2.0 8 valve engine from a mk3 golf and have been told its a relativerly straight forward conversion. i only have a basic knowledge of mechanics and even though have plenty of whilling helpers i am a little worrid about the task in hand? how easy are we talking? Do i have to weld in the mk3 engine mounts?
Been told i would need a diesel gearbox, do i need some sort of adapter plate?
also bee told i might need diesel sump and starter? What else would i need?
Or alternatly is there any one in the south east who could carry out this type of work?
Any advice will be much appreciated cheers
p.s van is 1.9 dg water cooled w/ 5speed box & engine includes ecu & loom

[Sir Chad]

Hi tiki25,
check out the wiki and search this forum for the basics.
I'd describe the GTi swap as quite a big task for a novice but with enough time and research it's relatively straight forward. Sourcing parts will take most of the time. Fabricating things like the exhaust and wiring require some engineering creativity.
You won't need a diesel gearbox but you will need a diesel bellhousing.
also your insurance costs will go up as the bus will need to be declared as modified.
Be prepared to offer the engine up and remove it a couple of times, in my experience read "hitting the chassis with a lump hammer" as a red herring, I had to plasma cut a section out and re-weld. It really depends on the exact engine you are fitting.
Good luck
Chad

[ginga]

I've done this to my 1.6d so I already had parts and hardest part was wiring. Its far from a professional job but so far Van has taken me round France and Spain and UK.

Exhaust I've welded myself and is on the fourth incarnation as I develop it. (not much ground clearance).

All the physical stuff was ok but I'm still running the Golf Fuse box as it has Ecu relays in it and I had to bypass immobiliser. If you do go ahead I have all the ECU pin numbers, voltages and connections if you need them.

cheers
Ginga

[slam_dunk]

Hi - just put a gti 8v K-Jet (EV) engine in to replace my 1,6d - it took about 3 weeks of evenings from when I first got the engine while I was offering stuff up and working out neat ways to do it - then I had 4 days off work and some help from a friend to actually put the thing together. The fun bit is that I knew it was possible from various forums, but be prepared for your engineering curve to go through the roof as you solve all the issues about where to put things. I used this early engine because it has very minimal electrics - basically just needed to add the ignition system (I got loom from a scirocco) A lot of people try and get hold of a diesel engine set up that is being broken to steal all the parts.

[HarryMann]

What fuel pump are you two using and have you had any problems with it in hot weather? Does it make an awful racket or pack up when hot?

ta!

[slam_dunk]

Makes a bad noise, yes. Don't know about the heat yeat - will keep you posted. I am using the pump with the accumulator and filter all together under the van. I didn't use the lifter pump as I managed to mount the main pump at the same level as the tant outlet.

[ginga]

I'm running a mk2 golf digifant main fuel pump. First one I used was really noisy. Cleaned it out which helped for a bit but I've just replaced it for a much quieter one, which seems to give a smoother response on acceleration too.

Used to have a mk2 jetta gti 16v which was kjet and fuel pump got noisy, very stuttery engine response then packed up all together after about a weeks driving (in middle of france).

Noise seems to get worse with driving time. Also seems to get better the fuller the fuel tank which i guess is what you'd expect.

Oh and changing filter next to it helped for a short while.
Ginga.

[Simon Baxter]

Avoid the MKIII as it will have a transponder type immobiliser which will mean using all the parts from one car, key, dash, ECU, immo box etc..

Not impossible, just long winded and potentially more expensive that just replacing what you already have.