1.8GTI motor in Mk1?

[hiho]

Hello all,

I'm after some pointers for fitting a 1.8GTI Cab motor in a Mk1. No, I havent gone off diesels, me and James (hessiethecrab) will be instaling this motor in his Mk 1. We have the manifolds, fuel injection system, ignition, oil cooler, radiator, gearbox and gearbox mount.

What we dont have is a fuel return line, drive shafts or any idea how to get the fuel injection working.

We would probably prefer to replace the fuel injection with a carburettor. What would be reccommended for this motor/car combo? WHat else do we need for this installation?

Cheers everyone!

Matt

[dubai gti]

Best to either go for a twin-weber set-up or what I run..a single 44IDF Weber and Oval Ramflo filter.....which is still pretty thirsty, but sounds great

[Peter Jones]

It'll pretty much bolt straight in. Is it a K-Jet or EFI motor? There's a few differences in what you have to block up depending on which you've got.

There's a bit of info in my Ziggy thread which was a GLD to Cabrio 1800 conversion. There's also a few other bits and pieces kicking about the place.

Keep asking questions and I'll hunt down the photos and posts for you.

Ziggy's thread. http://www.vwwatercooled.org.au/newf...ad.php?t=38301

My wreck to racecar thread's got a lot of info in it too along those lines (Link's in my sig below)

Easiest choice of carb for a daily is a twin barrel progressive like a Weber DGV,DGAV DCD etc on a Passat TS manifold. All you need to feed it is one fuel line and an electric pump, a Facet monoblock unit or similar should do the trick.

Bigger carbs need more fuel, if you go up to single or double sidedraughts then a Carter rotary vane pump is the answer.

Grab a couple of shots of you new motor and your destination engine bay and we'll be able to see what's going on a point you in the right direction.

Pete

[Peter Jones]

Oh, forgot to mention that to put an 1800 into a MK1 you need a GLD top radiator hose. The bottom one is the same.

Pete

[Jarred]

if you have all the Kjet injection gear, it's not too hard to put it into the diesel (since it was meant to be in a mk 1 after all)

so don't rule it out straight away. I'd only install the Kjet if I knew the system was in good working order before hand though.

[jayjay]

if you have all the Kjet injection gear, it's not too hard to put it into the diesel (since it was meant to be in a mk 1 after all)

so don't rule it out straight away. I'd only install the Kjet if I knew the system was in good working order before hand though.

make sure you actually have every single bit of k-jet gear too though.

otherwise ---> up the creek no paddle

[hiho]

Thanks everyone!

Its a K-jet motor with the injectors in the head (i think). I'll take some pics tonight.

Its going into an LS, so theres no return line. Other than installing a diesel tank and lines, are there any other workarounds here for the k-jet?

As for carburettor choices, will the standard 1.6L carby work? The desired outcome is a stronger, more reliable and fuel efficient car that doesnt wuss out on hills. With Weber carbs, does anyone have experience with jetting etc?

Cheers,

Matt

[hiho]

The motor is a JN, a low compression 1.8. Why would this motor need a fancy oil to air oil cooler?

[Oneofthegreats]

The motor is a JN, a low compression 1.8. Why would this motor need a fancy oil to air oil cooler?

I don't think there is any real need to run any oil cooler.

I don't even run one in my turbo'd setup..



If K-Jet conversion's are "not too hard", everyone would be doing it.

If you've got some good tools & can read & understand working component & wiring diagrams, you're half way there.

I'd suggest hainvg a look through both Pete J carby'd conversion & my own K-jet conversion.

I'm sure there is plenty of helpful info & pics.

If in doubt just ask.

http://www.vwwatercooled.org.au/newforum/upload/showthread.php?t=38088

This is the very simplified wiring diagram I made for the K-Jet electrical system quite some time ago

It doesn't have the TCI switch in there for electronic ignition, but I can draw that up if need be.

The fuel pump relay is also a ignition triggered setup. Meaning, if the engine stalls, the fuel pump will stop.

You can also just wire in a normal relay if need be & run straight off ignition power as I had to once I fitted the MSD ignition setup.

So as soon as you turn the ignition on, the fuel pump runs & if the engine stalls it will continue running. Not very safe, but a normal relay is also alot cheaper than a $100+ proper ignition triggered relay!




Hope this help's.

[Peter Jones]

Read this. http://www.diagnostic-assistance.co.uk/mech_inj.htm

If you can understand it go with the K-Jet.

You'll need big fuel lines (Two of them) and a tank to suit, diesel or injected cabby.

Pete

[Golf Loon]

I still love that diagram Tim.

Kjet install into a non kjet car is pretty difficult, especially if you are not familiar with the system. It uses high pressures so all componants must be in good shape and they are expensive to replace.

Thats why the Aussie answer was always to slap on a carby and have fun. Still works well, provided you can find a decent carby that works.

With the low cost of efi these days and the plethora of aftermarket stuff, thats a good option too.

Only onther cheap option would be to use the single point unit off a cordoba. Very few wires, fits on like a carby and gives great fuel economy.

[Jarred]

..
Only onther cheap option would be to use the single point unit off a cordoba. Very few wires, fits on like a carby and gives great fuel economy.

how would you go with wiring to the standard ECU? things like immobilisor and key barrels etc? Does it only need a small 'custom' loom, rather than a complete wiring loom?

Sorry, now that you bring it up, it's something that I was thinking about the other day.

[Oneofthegreats]

Read this. http://www.diagnostic-assistance.co.uk/mech_inj.htm

If you can understand it go with the K-Jet.

You'll need big fuel lines (Two of them) and a tank to suit, diesel or injected cabby.

Pete

Fuel line/hose should be approx 10mm.

My very first K-jet conversion I used just a hard type plastic (which is also flexible but can't do very tight radius') & robust fuel line from a place like Pirtek or Enzed, wrapped in a very strong conduit sort of material.

I have since decided to fabricate proper hard line from bundy tube.

From memory it was 3/8" as the Fittings were -6.

Any good Brake supplier like ABS etc, should have this sized bundy tube.





PS Thanks loon! Its probably still one of the best wiring diagrams I've ever come up with!

Its so simple its almost stupid!!!! haha.

[revnit]

what year model cab motor is it? ? if its the later k -jet with ecu, o2 sensor or emissions rubish wouldn't bother with it put on a carby, Ive always used the early basic k - jet ive been though 2 setups going from a 8v to 16v the early k - jet is easier all i run is the warm up reg and fuel pump rest is deleted can be hard to start at times but once shes running runs great.

As for your fuel you can run a high rate pump (for carby) from your LS tank to a swirl pot then run a (fuel injection) pump from that to the engine and run the return to the swirl pot make sure its a couple of litres this type of setup is common in older car going from carby to fuel injection other model of car don't have the option of diesel tanks. you can always pull your tank out and get fittings welded into it seen it done in the past.

[hessiethecrab]

I think I'm gonna keep it simple (at least initially) and go with a 32/36 weber. Anyone had any experience buying weber rebuild kits off ebay? What about jet sizes?

I'll put out a WTB in the for-sale forum for the other stuff I'll need (aircleaner, fuel pump etc)