Mk2 Golf GTi 20v Turbo Soon To Be Daily.....
Discussion
martin mrt said:
chrismc1977 said:
Cable change will never ever match the feel of the 020 setup sadly.
What?? The O2O rod change is crap, even when they were new it was rubbish You can indeed fit an O2J tower and cables to the O2A box yes
You are bang on with the O2J tower upgrade, this is on my To Do list. I'm planning on using the Seat Ibiza Cupra tower as i've tried one before in a mk2 and it was excellent. It also fits into a mk2 Golf tunnel and the mounting brackets nearly all line up. With a MK4 Golf/Leon/A3 tower you need to cut a couple of the tabs, redrill some holes and enlarge the opening in the chassis.
martin mrt said:
chrismc1977 said:
Cable change will never ever match the feel of the 020 setup sadly.
What?? The O2O rod change is crap, even when they were new it was rubbish You can indeed fit an O2J tower and cables to the O2A box yes
It’s just a pity the 020 boxes themselves had a tendency to spit the diff out. I always used to suffer flywheel & clutch woes as well - 195hp/150lbs/ft was on the limit for a 2Y
I had an O2O in an 8v Ibiza Cupra when it was near new, and thought it was rubbish when driven back to back with a 16v Cupra. The cable change clutch I’m also no fan of.
When I Converted my 8v Anniversary mk3 to a VR6 I done the O2J towerswap at the same time, this IMO was the best set up for the 5 speed O2A box.
Each to their own I guess.
For reference the shifter can come from any 99 on Polo Saloon/Estate TDI, Caddy TDI, Mk3 Ibiza TDI/Cupra or Córdoba TDI for best fitment into a mk2/3 or Corrado. As mentioned above Mk4 Golf platform cars have a shifter that will work but required more mods/manipulation to fit
When I Converted my 8v Anniversary mk3 to a VR6 I done the O2J towerswap at the same time, this IMO was the best set up for the 5 speed O2A box.
Each to their own I guess.
For reference the shifter can come from any 99 on Polo Saloon/Estate TDI, Caddy TDI, Mk3 Ibiza TDI/Cupra or Córdoba TDI for best fitment into a mk2/3 or Corrado. As mentioned above Mk4 Golf platform cars have a shifter that will work but required more mods/manipulation to fit
Edited by martin mrt on Monday 13th May 11:52
martin mrt said:
I had an O2O in an 8v Ibiza Cupra when it was near new, and thought it was rubbish when driven back to back with a 16v Cupra. The cable change clutch I’m also no fan of.
When I Converted my 8v Anniversary mk3 to a VR6 I done the O2J towerswap at the same time, this IMO was the best set up for the 5 speed O2A box.
Each to their own I guess.
For reference the shifter can come from any 99 on Polo Saloon/Estate TDI, Caddy TDI, Mk3 Ibiza TDI/Cupra or Córdoba TDI for best fitment into a mk2/3 or Corrado. As mentioned above Mk4 Golf platform cars have a shifter that will work but required more mods/manipulation to fit
Maybe Seat used different parts but my experience is based on owning several mk2 GTi’s in 8v & 16v guise.When I Converted my 8v Anniversary mk3 to a VR6 I done the O2J towerswap at the same time, this IMO was the best set up for the 5 speed O2A box.
Each to their own I guess.
For reference the shifter can come from any 99 on Polo Saloon/Estate TDI, Caddy TDI, Mk3 Ibiza TDI/Cupra or Córdoba TDI for best fitment into a mk2/3 or Corrado. As mentioned above Mk4 Golf platform cars have a shifter that will work but required more mods/manipulation to fit
Edited by martin mrt on Monday 13th May 11:52
Each to their own as you say
I dropped my Daughter back to her Mums at about 12.30 today and then lazed around the house for an hour or so. Once I’d got the lazing out of the way I headed outside to do some more to the Golf.
I decided to whip the engine out so I can give the engine bay a proper tidy up. Whoever my Brother got to do the conversion hadn’t been too fussed about it looking tidy and it was getting on my nerves. I decided to suspend the engine on my brace and then lower it and the gearbox onto my trolley and wheel it out. I got everything unplugged and the heater matrix hoses off and then all was left was the down pipe and driveshafts. I got the passenger side undone in a couple of minutes but the drivers side appears to have a couple of stripped bolt heads! The shafts haven’t been out since the Conversion was done so again it’s the people that did the conversion that have done this! I undid the hub nut and ball joint and pulled the shaft out of the hub then I can try and cut the rounded bolts off when I’ve got some more space.
The down pipe was pretty easy to undo although I had to lay across the engine which was comfortable
With the down pipe off I hooked up the engine brace, undid the mounts and lowered the engine and gearbox down onto my trolley.
With it out of the car I can now tidy all the wiring, clean the whole engine bay, sand and paint the surface rust and generally make it look a bit more presentable. I’ll also tidy the engine up, replace some gaskets, paint the block and clean up the gearbox
I decided to whip the engine out so I can give the engine bay a proper tidy up. Whoever my Brother got to do the conversion hadn’t been too fussed about it looking tidy and it was getting on my nerves. I decided to suspend the engine on my brace and then lower it and the gearbox onto my trolley and wheel it out. I got everything unplugged and the heater matrix hoses off and then all was left was the down pipe and driveshafts. I got the passenger side undone in a couple of minutes but the drivers side appears to have a couple of stripped bolt heads! The shafts haven’t been out since the Conversion was done so again it’s the people that did the conversion that have done this! I undid the hub nut and ball joint and pulled the shaft out of the hub then I can try and cut the rounded bolts off when I’ve got some more space.
The down pipe was pretty easy to undo although I had to lay across the engine which was comfortable
With the down pipe off I hooked up the engine brace, undid the mounts and lowered the engine and gearbox down onto my trolley.
With it out of the car I can now tidy all the wiring, clean the whole engine bay, sand and paint the surface rust and generally make it look a bit more presentable. I’ll also tidy the engine up, replace some gaskets, paint the block and clean up the gearbox
Right, update time!
I’ve been snowed under at work recently and when I haven’t been working Mrs Sammo has been finding things for me to do that doesn’t involve going near the Golf! Thankfully I’ve got two weeks off work so the intention was to spend one week on the Golf and the second week doing family things. Well this week is the first week and it’s rained on three of the four days so far! That’s left me with a few dry hours on Monday and most of today to get some stuff done. Fingers crossed for tomorrow!
Anyway, at the last update the engine was out and ready to be stripped down and cleaned. First thing was to get the old K03 turbo off along with the rear engine mount. Then I could sand and paint the rear of the block. Now I forgot to take pictures of this stage because it was a pain in the arse but suffice to say the old turbo came off, I sanded and painted the rear of the block and then the new turbo went on.
Before tackling the front of the engine I decided to remove the rocker cover, clean it and paint it. It needed to come off anyway to replace the leaking rocker cover gasket.
Boring silver rocker cover with leaking gasket...
Slightly nicer looking crackle painted rocker cover.
While I was at it I decided to fit the silicone TIP that I’d bought. The standard turbo inlet pipes are a bit restrictive and generally not great so it was always on the list to be replaced.
With the back of the engine painted, K03s turbo fitted and the rocker cover painted and gasket replaced it was time to move to the front of the engine. This meant removing the inlet manifold, alternator and then anything else that was going to get in my way! In the end it was easier just to remove everything.
Once it was all off I got busy with the wire wheel and make a rusty mess all over the floor (and me!) and then cracked out the engine paint again
With the block sorted it was time to move onto the inlet manifold. First it got dunked in my bucket of degreaser and then got a good scrub down with a wire brush. Once it was looking a bit cleaner I attacked it with the crackle paint. I had to find something to cover the injector holes with and thankfully four 2p pieces did the job perfectly
That was then left in the sun (on top of the Bbq in fact) to dry while I started looking at what else I could paint hehe.
Now on the 20v engines there is this huge aluminium bracket that bolts to the front of the block and holds the alternator, PAS pump and A/C compressor in place. It does a great job in a Mk4 Golf but on a Mk2 Golf with no power steering and no A/C it looks a bit out of place. I’ve heard of people cutting them down a bit to tidy everything up so after a bit of hunting through the shed for my saw I had a quick measure up and set to work giving it a trim up!
I even managed to cut it straight One that was done it got dunked in the degreaser, given a good scrub and then painted.
That was then left in the sun to dry as well.
Now that I was waiting for bits to dry it seemed like a good time to tidy up and then start getting ready to go to my evening job. I need to order a new thermostat, thermostat housing gasket, oil cooler housing gasket and the metal water pipe that runs from the water pump round the side of the engine has got a hole in it from me wire brushing it so I need to get a spot of weld put on it seeing as you can’t buy them new anymore. In an effort to make the engine bay look as tidy as possible I’ve also ordered some lengths of black silicone hose, joiners and elbows for the cooling system. I also need to go and pick up a couple of cans of Atlas Grey so I can tidy up the engine bay.
The list is getting shorter but the weather isn’t doing me any favours at the moment!
I’ve been snowed under at work recently and when I haven’t been working Mrs Sammo has been finding things for me to do that doesn’t involve going near the Golf! Thankfully I’ve got two weeks off work so the intention was to spend one week on the Golf and the second week doing family things. Well this week is the first week and it’s rained on three of the four days so far! That’s left me with a few dry hours on Monday and most of today to get some stuff done. Fingers crossed for tomorrow!
Anyway, at the last update the engine was out and ready to be stripped down and cleaned. First thing was to get the old K03 turbo off along with the rear engine mount. Then I could sand and paint the rear of the block. Now I forgot to take pictures of this stage because it was a pain in the arse but suffice to say the old turbo came off, I sanded and painted the rear of the block and then the new turbo went on.
Before tackling the front of the engine I decided to remove the rocker cover, clean it and paint it. It needed to come off anyway to replace the leaking rocker cover gasket.
Boring silver rocker cover with leaking gasket...
Slightly nicer looking crackle painted rocker cover.
While I was at it I decided to fit the silicone TIP that I’d bought. The standard turbo inlet pipes are a bit restrictive and generally not great so it was always on the list to be replaced.
With the back of the engine painted, K03s turbo fitted and the rocker cover painted and gasket replaced it was time to move to the front of the engine. This meant removing the inlet manifold, alternator and then anything else that was going to get in my way! In the end it was easier just to remove everything.
Once it was all off I got busy with the wire wheel and make a rusty mess all over the floor (and me!) and then cracked out the engine paint again
With the block sorted it was time to move onto the inlet manifold. First it got dunked in my bucket of degreaser and then got a good scrub down with a wire brush. Once it was looking a bit cleaner I attacked it with the crackle paint. I had to find something to cover the injector holes with and thankfully four 2p pieces did the job perfectly
That was then left in the sun (on top of the Bbq in fact) to dry while I started looking at what else I could paint hehe.
Now on the 20v engines there is this huge aluminium bracket that bolts to the front of the block and holds the alternator, PAS pump and A/C compressor in place. It does a great job in a Mk4 Golf but on a Mk2 Golf with no power steering and no A/C it looks a bit out of place. I’ve heard of people cutting them down a bit to tidy everything up so after a bit of hunting through the shed for my saw I had a quick measure up and set to work giving it a trim up!
I even managed to cut it straight
One that was done it got dunked in the degreaser, given a good scrub and then painted. 
That was then left in the sun to dry as well.
Now that I was waiting for bits to dry it seemed like a good time to tidy up and then start getting ready to go to my evening job. I need to order a new thermostat, thermostat housing gasket, oil cooler housing gasket and the metal water pipe that runs from the water pump round the side of the engine has got a hole in it from me wire brushing it so I need to get a spot of weld put on it seeing as you can’t buy them new anymore. In an effort to make the engine bay look as tidy as possible I’ve also ordered some lengths of black silicone hose, joiners and elbows for the cooling system. I also need to go and pick up a couple of cans of Atlas Grey so I can tidy up the engine bay.
The list is getting shorter but the weather isn’t doing me any favours at the moment!
chrismc1977 said:
martin mrt said:
chrismc1977 said:
Cable change will never ever match the feel of the 020 setup sadly.
What?? The O2O rod change is crap, even when they were new it was rubbish You can indeed fit an O2J tower and cables to the O2A box yes
It’s just a pity the 020 boxes themselves had a tendency to spit the diff out. I always used to suffer flywheel & clutch woes as well - 195hp/150lbs/ft was on the limit for a 2Y
My Daughter has gone out for the day with her Cousins and Mrs Sammo and I are going for afternoon tea later so I thought I’d get a quick hour in on the Golf this morning
Today’s mission was to degrease and jet wash the engine bay. I don’t think it was particularly clean when the conversion was done and then the car has done lots of sitting around ever since. I’ve found plenty of snails, spiders and evidence of mice as well when removing things so this clean was long overdue.
After laying on about 2L of degreaser I left it to soak for a few minutes and then went to town with the jet wash! It’s quite hard to tell from the pictures but it’s made a world of difference!
Before...
After (the engine wasn’t there when I was washing. I rolled it back in after and then remembered to take a picture!)
Thankfully today is a sunny day so I’ve left the bonnet up to let it all dry out. Depending on tomorrow’s weather and what secret plans have been prepared for me I am going to try and tidy up the loom a bit. I’ve got plenty of loom tape just waiting to be used so fingers crossed I get some time to crack on with it
Today’s mission was to degrease and jet wash the engine bay. I don’t think it was particularly clean when the conversion was done and then the car has done lots of sitting around ever since. I’ve found plenty of snails, spiders and evidence of mice as well when removing things so this clean was long overdue.
After laying on about 2L of degreaser I left it to soak for a few minutes and then went to town with the jet wash! It’s quite hard to tell from the pictures but it’s made a world of difference!
Before...
After (the engine wasn’t there when I was washing. I rolled it back in after and then remembered to take a picture!)
Thankfully today is a sunny day so I’ve left the bonnet up to let it all dry out. Depending on tomorrow’s weather and what secret plans have been prepared for me I am going to try and tidy up the loom a bit. I’ve got plenty of loom tape just waiting to be used so fingers crossed I get some time to crack on with it
After ordering some cooling system bits last week I arrived home this morning from a day out with the kids yesterday to find it had all arrived already
I’m still waiting on the various gaskets to arrive so that I can refit things and I still need to get the metal pipe welded up. Today though I’ll get on with re-wrapping the loom I think
I’m still waiting on the various gaskets to arrive so that I can refit things and I still need to get the metal pipe welded up. Today though I’ll get on with re-wrapping the loom I think
I managed a couple more hours on the Golf this afternoon before getting ready for the evening job!
I pulled the various bits of loom out from wherever they had been bent and squashed into so they were all sitting out straight in the engine bay. I still can’t get over how crap the wiring has been routed in this car! There are bits everywhere! I did my best with moving earthing points and grouped together as many bits of loom as possible to run across the bulkhead rather than the five separate looms that were there previously!
I think it’s looking much neater compared to the nest of wires that it did have!
It’s not finished yet but it’s getting there
I pulled the various bits of loom out from wherever they had been bent and squashed into so they were all sitting out straight in the engine bay. I still can’t get over how crap the wiring has been routed in this car! There are bits everywhere! I did my best with moving earthing points and grouped together as many bits of loom as possible to run across the bulkhead rather than the five separate looms that were there previously!
I think it’s looking much neater compared to the nest of wires that it did have!
It’s not finished yet but it’s getting there
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