T25 GTi engine conversion help please!

Post by **timot25** » 10 Jul 2007, 14:10

Hello All,
I am new to the VW scene since buying a 1986 T25 panel van off a guy who blew the head gasket of the original 1.6 diesel and was mid way through installing a 2l Mark 3 Golf GTi engine. I therefore bought the van as a non runner with the aim to get it running as a hopefully reliable mode of transport and to kit out the inside as a bit of a camper. Not sure whether the budget will stretch to putting windows in yet or not, but would like to.

The bodywork is pretty sound and the engine is in. Having problems locating the engine code, the sticker on the top of the timing belt cover has partly disintegrated, I can read 2E which I assume is the first part of the engine code?

The fuel tank is in but with four wires trailing out behind it, the red/yel and brown ones are for the fuel pump, not sure what the other two are for as it looks like the gauge sender is already connected?

As for the engine wiring etc, the ECU and loom is all there, i'm just struggling to link everything up. So, I have several questions for which I apologise in advance! I do have some mechanical knowledge having built a GTM Spyder Kit car but then the wiring seemed particularly easy. So, here goes with the questions. If anyone lives near the Walton-on-Thames area in Surrey and feels they could spare me an afternoon helping get this thing going, that would be much appreciated!

1 - There is no lamda sensor in the exhaust manifold, will this affect the ECU's ability to perform?

2 - Fuel rail, which is in and which return (1or2 see pics). Where should the vacuum T piece go (3). What is the other small exiting pipe beneath this pressure/vacuum bit go not seen in pic (4).
[IMG:490:367]http://i196.photobucket.com/albums/aa28 ... elrail.jpg[/img]
3 - What should this ?breather connection (5) be connected to?
[IMG:490:367]http://i196.photobucket.com/albums/aa28 ... eather.jpg[/img]
4 - Opposite end of intake manifold, (6) what pipe should go here? Is it the brake vacuum servo pipe?
[IMG:490:367]http://i196.photobucket.com/albums/aa28 ... intake.jpg[/img]
5 - What goes into here (7)? Should it be a sensor of some sort?
[IMG:490:367]http://i196.photobucket.com/albums/aa28 ... nmaybe.jpg[/img]
6 - What pipe goes on here (8)? Is it from the coolant expansion tank cap?
[IMG:490:367]http://i196.photobucket.com/albums/aa28 ... pmaybe.jpg[/img]

Many thanks in advance if you've made it to the end of this long post firstly, and secondly if you are able to offer any advice please!

Tim

Post by **HarryMann** » 10 Jul 2007, 16:12

Nice detailed request for info there Tim... 1st post an'all

I've asked someone to help with this for you... hold fire for a bit please.

Post by **ELVIS** » 10 Jul 2007, 17:33

try www.clubgti.com/forum/ they will deffo know

Post by **timot25** » 10 Jul 2007, 17:34

That's great, thank you for the quick responses.

Post by **andysimpson** » 10 Jul 2007, 18:06

1 fuel in
2 fuel out
3 connects to inlet manifold, other pipe could be mfa or ecu
5 should connect to no 7 and then onto the pipe near the throttle in the pic.
6 brake servo
8 would go to header tank in a golf, block it off for a t3.

Lambda sensor will be required.

Post by **timot25** » 10 Jul 2007, 19:33

Ah ha! Thank you. The intake pipe that fits on to the throttle body has a hole to accept the pipe next to it, but also has another hole which I guess number 5 might connect to too. I'm sure a sensor of some sort must be involved at number 7 as it has a large circlip type thing for it. I may be a bit stuffed with regard to the Lambda sensor as there is nowhere on the exhast manifold to put one. Is there an easy way round this?

There is nowhere on the ECU for a vacuum pipe and I don't know what an mfa is with regard to number 3!

Thanks for all the help so far, much appreciated.
Tim.

Post by **andysimpson** » 10 Jul 2007, 19:51

timot25 wrote:Ah ha! Thank you. The intake pipe that fits on to the throttle body has a hole to accept the pipe next to it, but also has another hole which I guess number 5 might connect to too. I'm sure a sensor of some sort must be involved at number 7 as it has a large circlip type thing for it. I may be a bit stuffed with regard to the Lambda sensor as there is nowhere on the exhast manifold to put one. Is there an easy way round this?

There is nowhere on the ECU for a vacuum pipe and I don't know what an mfa is with regard to number 3!

Thanks for all the help so far, much appreciated.
Tim.

No5 connects on the rubber pipe between throttle and air flow meter.
N0 7 just has a pipe which comes out and instantly reduces in size.

Lambda sensor is best in exhaust front pipe as near to manifold as possible to get nice and hot.

The mfa is the display on the dash which tells lies about mpg.

Post by **timot25** » 10 Jul 2007, 20:51

Perfect, thanks Andy. I need to find a new pipe then. Would anyone have the wiring configuration for THE ECU that goes with the 2E engine, and where might I find the code stamped on the block as the sticker has disintegrated.

Post by **andysimpson** » 10 Jul 2007, 21:17

timot25 wrote:Perfect, thanks Andy. I need to find a new pipe then. Would anyone have the wiring configuration for THE ECU that goes with the 2E engine, and where might I find the code stamped on the block as the sticker has disintegrated.

A new from vw is about £30.

Sorry can't help on wiring diagram, if it was newer i could.

Post by **HarryMann** » 10 Jul 2007, 21:33

Regards the lambda sensor fitting, when Subaru conversions need these (pretty well always) a boss is quite easily welded into the pipe at a convenient point, the only thing to follow I think is whether the original has it exposed or shrouded a bit, however near the manifold it is.

If you are handy tapping a boss and MIG'ing it in - might be worth just copying the original.

Post by **andysimpson** » 10 Jul 2007, 22:14

HarryMann wrote:Regards the lambda sensor fitting, when Subaru conversions need these (pretty well always) a boss is quite easily welded into the pipe at a convenient point, the only thing to follow I think is whether the original has it exposed or shrouded a bit, however near the manifold it is.

If you are handy tapping a boss and MIG'ing it in - might be worth just copying the original.

Fully exposed as are most vw lambda sensors.

Post by **HarryMann** » 10 Jul 2007, 23:21

Code on block might be stamped near distributor boss on block... flat area forward of it below cyl 3 ?

Thanks - Have now put most of this in the Wikipedia on Alt Engines, Golf

Post by **timot25** » 11 Jul 2007, 12:52

Superb! Thanks for all the useful info. Should be up and running in no time, maybe!