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

[Stan]

I have a 1.6sr mk4 Golf MY2000, the car in my sig.
Actually a nice little car, but I wanted more zing.
I am a guy - so i decided to pull a perfectly working daily driver apart and make a project of it.

So at this annual leave I decided it was time. Parts were sourced mostly through Matt at Camden GTI - a nicer guy you won't find, and some invaluable advice as well - like "Dont build a car you can buy..."

Other bits like wheels and brakes sourced on the forum here.

I gave myself 2 weeks and so far it has been three, with wiring being the main issue (it could also be ECU related), and the car still not on the road...

Base car is an 2000 model AKL VW Golf Mk4. It is supposed to be a special edition, but really it means a rally with pretty seats. About 220K klms on the clock and a nice straight runner, with a nice body. Engine is fine, it's just that it is the 1.6

Engine is an AGU Audi A3 1.8 Turbo, stock.

I got the entire front subframe, engine, gearbox, driveshafts, ECU and Loom (well most of it), exhaust and ancilliaries except for the Aircond compressor- but I had one of those.

I actually left the AC and braking circuits in the car , undisturbed to do this.

AC became tricky to work around, but it worked.

This has step by step pics but here are a couple of teasers to start you off:





remember this was a working daily driver.

Build was commenced in a garage slightly bigger than a single car one.

Suffice to say, it's taking a while and Mrs Stan is not impressed anymore...

[GOLFBALLS]

Haha! Bloody classic. I like the "dont build a car you can buy" line, and the fact you ignored it!!
Good onya mate

[Stan]

Seemed cheaper than trading up to a GTI, but I dont think it will in the end....

[Jmac]

Ah well when its up and running reward yourself by tuning it. Whats the issue with wiring? I deal with these a fair bit.

cheers
Jmac

[Stan]

plugs from mains looms to connectors in plenum chamber have different wiring, slightly

Also wondering about my instrument cluster and the ECU, signals to fuel pump relay....car cranks but wont fire.

[Stan]

More pics

Start with a perfectly good car, a smallish garage and a couple of weeks leave...







Standard 1.6sr:





Engine cover off, take plenty of reference pics too (wont put all those here



This is what is going in: Audi A3 AGU 1.8T




What could possibly go wrong???

[Stan]

Easiest way to do it in may case was to pull the front out of the car, raise it up and pull out the whole front subframe, with engine, gearbox and driveshafts etc, all in one go:

Remove the bumber and grille (vortex had a good post on this)







I initially didnt want to remove the bonnet, but had to in the end to get the chain hoist nice and squre overhead.
White tape in pic is either labelling (you just cant do enough of it), sticking screws that come out near their holes, or to cover air intakes etc...

Front bar, front clip and headlights would have come off in just two complete pieces; however, i have airconditioning, so they have to come out in pieces to work around leaving the ac circuit fully intact.

AC cooler is in front of the radiator:

[Water Boy]

Good work Stan. I thought you werent around this forum since we meet at the photoshoot night. Huge props on doing the conversion.

[dylan8]

Will be watching this.
Have this in the back of my mind for when something major goes wrong with the bora.
Doing all the work yourself? Have you done a engine swap before?

[Stan]

I always look in, just not a big poster. When this is on the road again , i' will bring it along to a nightout. Met lots of nice guys there, and will catch up again soon