2.0 conversion – now runs.

Forums Reference Tuning & upgrades 2.0 conversion – now runs.

This topic contains 81 replies, has 11 voices, and was last updated by  no such user 9 years, 2 months ago.

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  • #523

    no such user
    Participant

    DannyP came over today and was a complete star – we now have 2.0 motor on the floor, out of the Passat I bought. I also have all of the mounting hardware and the cable-change gearbox gubbins. This should enable me to go 2.0 and cable change in one hit.

    Engine coming out of the stricken Passat:

    PB030001S.jpg

    All the VW goodness wrung out of it and sitting on the floor in front of the Golf that it is destined for:

    PB030002S.jpg

    There’s a fair old distance to cover, but now the stuff’s actually in the workshop and I’m going to be falling over it there’s a lot more incentive to get it in and sorted and pushing on.

    After a bit of poking around my (incredibly untidy) workshop Dan actually found a Digifant manifold, fuel rail, loom and ECU, so it’s likely the 2.0 will be fed by that – easy to chip it and tweak it up than the later system. Still, it’s nice to have a choice!

    The only slightly annoying thing is I never got to try out the hard-won K-jet dizzi, on the Weber – it was supposed to have an aggressive advance curve on it. Ahh well, on to bigger and better things [:)]

    #3588

    Chris S
    Moderator

    The only slightly annoying thing is I never got to try out the hard-won K-jet dizzi, on the Weber – it was supposed to have an aggressive advance curve on it. Ahh well, on to bigger and better things

    Exactly just make sure it is lambda controlled, then I have a nice 10/15 bhp chip for you

    #3590

    no such user
    Participant

    Not exactly sure what’s going to happen Chris. The ECU from the Passat is a Siemens one. Danny and I were a little puzzled by this, as we thought Digifant was a Bosch thing, or is it the case that it’s just a name for a ‘system’ of programming?

    It’s a brave new world!

    #3591

    Chris S
    Moderator

    As long as your ECU box has either 037 906 022GD or 037 997 023SX as the part nr then its ok.

    #3592

    no such user
    Participant

    Right, let’s check a few part numbers and see what we’ve got…..

    037 906 022 FL is the Siemens

    0261 200 298 is the Bosch.

    Well, neither of them tally. A quick check reveals that (thankfully) the lift pump I’ve been hoarding is the right one, at least!

    #3595

    Chris S
    Moderator

    That nr is also ok, its the computer for the catalysed motor, it is as are all 2E motors/management computers meant to run with a lambda sonde.

    #3601

    no such user
    Participant

    What about the Bosch? I’m thinking that’s not got the lambda input.

    #3602

    Chris S
    Moderator

    They all have to have a lambda input on the 2E motor or they go into limp home mode,
    btw all the lambda does is to constantly fine tune the fuel mixture so it is at the optimum burn ratio all of the time, so there is no excess unuseable fuel or air, I.E too rich or too weak

    #3611

    stephcasscar
    Member

    Your garage is about as busy as one of mine. lol

    It’ll be alot easier and quicker with 2 of you doing the swap for both the engine and gearbox. If your short any digi gubbins give me a shout, i’ll have a butchers, if got a few bit and have no plans on using it.

    #3615

    no such user
    Participant

    Cheers Steph – if you’re up Bristol-way at any point you’re welcome to stop by for a cuppa and a chat.

    The pictures aren’t telling the whole story – there’s a whole lot more stuff past the Golf – a couple of Audi 5 cylinder motors, the welder, press and loads of junk/parts on various shelves. After two years I’m just settling in!

    Danny’s about an hour up the road, so comes down for the occasional weekend and gives me a proverbial kick up the arse – I’m back on my own now after we got just a bucketload of stuff sorted last weekend – I’ve not even mentioned the T25 pick up with the Audi turbo motor that we took out for a first test drive and tidied a load of jobs up on!

    I enjoy working as a team WAY more than on my own, hence the huge amount of stuff we got done :)

    #3616

    no such user
    Participant

    I just need to get my arse moving on my own projects now

    #2703

    no such user
    Participant

    A few pictures from stripping down the Passat lump last night are here: http://diamondhell.com/component/option,com_rsgallery2/Itemid,29/catid,11/

    You busy on Sunday, Danny?

    #2736

    no such user
    Participant

    by the look of things atm have the week end off :)

    #3775

    no such user
    Participant

    Lots more done. We’ve come up against a really big issue with the exhaust. This was half-expected, but we thought the pictures in the gallery meant that we would just need to cut and shut the Rallye downpipe a bit.

    Oh, no, that’s not the case. Not entirely decided which manifold to use yet – the Rallye manifold puts the offside downpipe VERY close to the steering column and especially the knuckle, AND looking at the footwell clearance. The Passat manifold leaves it over the angle-drive to the rear. It appears that to allow the downpipes to come through without being too close to the shift mechanism, steering rack or angle drive it’s going to be worth cutting out a section of the tunnel and welding back in a section to effectively create a clutch foot-rest, which will give a lot more space to allow heat dissipation, which has to be the biggest issue here (after the lack of actual space).

    This is a pretty radical approach to take, as the tunnel is one of the key pieces of the car that makes the shell so stiff. I’m going to go for this though as it’s not just the key to unleashing the 2.0, it means that the exhaust (in particular the tricky downpipes) will support more powerful motors, should I choose to go for them.

    I’m thinking I might go cable clutch, as DannyP has, rather than the hydraulic clutch from the Passat – it’s smaller and lighter.

    The main thing is to get the exhaust sorted and the car back and fighting fit for 2008 track-season. :-)

    Lots more photos on Diamondhell.com as above.

    #3881

    no such user
    Participant

    I’ve got a welder’s suntan today.

    Looks like I spent rather too long tacking the Y-pipe together last night! [:o)]

    Pictures are at: http://diamondhell.com/component/option,com_rsgallery2/Itemid,29/catid,20/

    That’s the exhaust done. Now I need to check the fit in the cut-out hole and then stitch in some plate over that. Once that’s done I can get serious about the engine and gearbox.

    I’ve also ordered the cable clutch actuator and boot and a few other bits, although VW UK are denying all knowledge about the Mexican Golf waterpipe I need!

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