Swapping the 1.6L for a 1.8L and 5 speed

[GRN_VAGN]

Hey all

Going to be swapping in a rebuilt 1.8L and a 5 speed box into my MK1 in a few weeks. anything i should look out for?

Also are the 1.6L cam wheel same as the 1.8L?
and how did ya go about blocking the 4 holes above the inlet manifold?
Im guessing they for the K-Jet?

Regards
Dan

[SpeciP3]

if memory serves me correct, the four holes are for efi, k-jet uses just one injection point much like a carby.
someone correct me if i'm wrong..

there are plenty of stories about conversions are, try using the search function, or trawling the conversions section.

good luck with it mate.

[Peter Jones]

Also are the 1.6L cam wheel same as the 1.8L?

Yes, and so is the timing belt.

and how did ya go about blocking the 4 holes above the inlet manifold?
Im guessing they for the K-Jet?

Yep, they're the injector holders, they should unscrew. You can drop a coin down the hole and screw the holder back into place to block them off or beetle gearbox drain plugs screw in there too.

You can also leave a set of injectors in there or fill them up with Devcon.

Pete

[GRN_VAGN]

Cheers pete, ill have a looky soon, gotta finish the 18RG motor first, then drop that in the celica. then ill tend to the golf

And cheers for the tip on the coin

[Peter Jones]

And cheers for the tip on the coin

We did this trick on GoLfMans 1800. I think it was 10cent pieces we used.

If your car has the plastic insulator on the end of the injector holder you'll need to remove those. Sometimes they come out with the holder other times they get stuck in the head. It's best to do the work with the manifold off so you can get at the underside of the injector holes if you need to.

We used a little bit of Permatex blue RTV sealant. (Silicone) on the coins to ensure a good seal.

On the later heads there's an air gallery as well that connects to vacuum. There's a small plastic fitting between inlet ports 3 & 4. Using the coins blocks this off internally but I'd block the fitting off too just to be sure.

This air gallery draws air from around the injectors to keep them cool it'll only be on the motors with injector insulators.

Pete

[gldgti]

if memory serves me correct, the four holes are for efi, k-jet uses just one injection point much like a carby.
someone correct me if i'm wrong..

correction: k-jet uses a total of 5 injectors, one in each port in the head (the holes described) and a single cold start injector in the manifold plenum.

there is a single point injection system that was fitted to the 1.8L non-intereference motors (ADY and ADZ, and a few others i think) which is found on some mk3 CL's, SEAT cordoba's etc.

[Jarred]

I actually think it was 5 cent pieces wasn't it pete?

Make sure you have matching CV's for the gearbox.

4 speed ones are 90mm, 5 speed ones are 100mm.

[GRN_VAGN]

ooo didnt know that, cheers Jarred.

By CV, im guessing the bit that joins to either side of the gearbox?

[Jarred]

yea, but the part actually on the Driveshaft.

[GRN_VAGN]

so what actuall part is different? the CV on the end of the shaft? can the large CV be put on current shaft and used that way?

[Jarred]

so what actuall part is different? the CV on the end of the shaft? can the large CV be put on current shaft and used that way?

yes, but not straight on. the driveshafts need to be 'cleared' to fir the bigger CV.s i'm unsure on exact specs, cause I've never done it, but i've seen it done with an angle grinder , the proper way would be to get a machine shop to take off the reg distance, or find 90mm driveshaft flanges (bit on the gbox) i believe they're rareish and hard to find.

[gldgti]

you can also just put 90mm flanges on the 5-speed box.

[Jarred]

you can also just put 90mm flanges on the 5-speed box.

The impression I got, although I havn't looked very far into it, was that 90mm flanges only came on a 5 speed mk 1's, ie GTI's, and hence, not many floating around, unless they can be bought brandnew?

[dub be good to me]

I had no problem bolting my 90mm CVs to a diesel 5spd..

EDIT: Now that I think about it the box was from a Mk2 Diesel.. mid 80's I think

[gldgti]

The impression I got, although I havn't looked very far into it, was that 90mm flanges only came on a 5 speed mk 1's, ie GTI's, and hence, not many floating around, unless they can be bought brandnew?

90mm flanges are everywhere..... 4 speeds