Stan's Epic Golf Build: 1.6se becomes 1.8T

[Stan]

Time for some more:

Remember to label stuff. i labelled the bits I pulled off the old engine and then made labels for the corresponding bits on the new one.





Any screws or bolts removed were either put back into the holes they came from or taped and labelled next to where they went.

If it is a duct or hole, tape it up or stuff a rag in it - bits of debris in an engine can kill it - even more so with a turbo:




With everything undone, labelled and taped up. The engine is supported with the chain hoist.
Time to undo the engine mounts. I checked the part numbers and they are exactly the same. So Initially I undid the bolts that attach the mount to the engine - These two:



And similar on the other side. This allows the engine to drop away, free of the mounts. When the engine was out I completely removed and exchanged the mounts , as the others were a good 100K kms newer.

With the mounts undone, the whole front subframe is held in by 4 bolts. You can reach them easily enough without getting under the subframe - so if something goes wrong, you dont end up with an engine on your head....

This is the AGU, but it shows where 3 of the 4 subframe bolts are. these bolts actually go in the other way around, they are in this way so they dont fall out:



Same from under the car. Circled is the o2 sensor housing - it is simply a cover and two cables clip together beneath it. Undo this connection, as the forward cable is attached a sensor on the downpipe:



At this point the engine is held by the hoist and ready to be lowered onto the dolly. Go very slowly as something is sure to be still attached. As best you can, run your hands around the engine to feel for any possible snags. If something needs undoing , stop the lowering, undo it and continue. I had a mate helping me at this stage to help guide the engine, an extra pair of eyes and this is potentially dangerous - good the have someone else there:



Things snag up a bit, so take your time and deal with them, but in a very short time you get this:

[dylan8]

Between you and James im keener then ever to do mine!
Dont see many threads with pictures, look forward to the rest.

[Stan]

it's kind of fun, but I am at the point that I wish it was finished.
My mistake was that it is my daily driver - it takes for more time to do right than I had planned.

Yeah, James' project will be interesting to watch as well.

Happy to give both of you any help I can.

If you want a specific pic, ask now - I might already have it , or can take it before the project ends

[Golf Loon]

Nice thread Stan. Are you any further forward with the wiring?

[Stan]

Thanks mate, you've been an awesome help.

Nope. Still the same issues, something is up and I cant find it. A few of the wires are different colours, but they still go to the same places according to AKL and AGU wiring diagrams.

Car still cranks but doesnt fire - i know for sure it's not fuelling - pump and relay are good, so i'll be @#$%ed as to what is going on.

[Jmac]

Replied with some info on the Mk4 section mate

[GOLFBALLS]

You sure its not something simple like a faulty crank angle sensor or something? If thats dodgy the engine will crank over but not fire iirc...

[Stan]

crank angle sensor is fine, vagcom shows 200+ rpm on cranking - so the sensor is working. good idea though

[GOLFBALLS]

Did you find out if the plugs are sparking?
Does the 1.8t you're using have the seperately amplified coilpacks, or the individually amped ones?
And i know i'm scraping at the barrel here but did you fit a new fuel pressure regulator. They are prone to fail...

Just making sure you havent forgotten the simple stuff as these faults often are

[Stan]

spark at plugs
separate amp for coil packs
original fuel pressure regulator
with fuel pump relay hotwired there is fuel at the plugs

Battery to relay circuit checks out as does the pump to relay circuit - that leaves ecu to relay, a dud earth or something.
All fuses ok
ecu/engine was from a pranged car, but the airbags didnt go off, so there goes my theory that the ecu was holding back the injectors and fuel pump relay.... or maybe it is, nothing to suggest this on vagcom though

on cranking only 5 volts at fuel pump and 5 volts across the injectors

Golfballs i think you are absolutely right - it's a simple thing, it just comes to tracking it down

[Stan]

Jmac has pointed out that the wiring is different on the fuel pump relay between the two ecu/cars, i think were are onto something now

[Stan]

SUCCESS !!! Got the car to run after changing a wire in the plenum chamber from the brown plug to the orange one, which involves the fuel pump relay!


Thanks guys, especially Gav who spent a lot of time on the phone with me and Jmac who discovered the actual wire (after a fair bit of time checking out circuit diagrams - he is the wiring guru, will have to get this guy to chip it later).

Also to Steve who offered me the chance to try his computer and check out his cars if need be.

What a great forum

stand by for more pics and updates...

[GoLfMan]

glad to hear that you have progress

[AlexRO]

good to hear !

[velly_16v_cab]

epic build fella...glad you got it sorted in the end!