Mk1 2.0 16v abf conversion

[dado]

my project is looking much better after arrival of "japanese vr6" today. they call them this name as they are purchased and send from japan as a vr6. i believe this has happened i few time before.looking great with 60000km on the clock.have a look http://photobucket.com/wheels_03

[Preen59]

I'm happy for you dude, but you've posted to photobucket email you use to send pics to photobucket as the link, not your album.. :)

[Jarred]

curious to find out more about getting a half cut from Japan? where did you source it from if you dont mind me asking?

[cartertronic]

Perfect timing! Hopefully we can help each other out, although I won't be starting for a little while yet.. Too bad you're in Sydney, would've liked to lend you a hand in preparation for my conversion!

Good luck! Really looking forward to reading this one! :banana:

[dado]

thanks mate, currently in talks-negotiations with Matt from Camden GTI so he may be doing this conversion due to lack of my time and experience.also car booked with panelbeater for respray as i wont be doing this in the backyard either.in saying that i will still be fixing minor things as i am sure there will be plenty of them to.

[dado]

just had a look at my 020 gearbox code is FF 14062 is this good or bad any idea on the gear ratio

[Jarred]

From memory, that has the same ratios as the standard 4 speeds, but with an 'overdrive' 5th. have a quick search, plenty of links have been posted before in relation to gearbox ratios.

[Golf Loon]

Mik, this is what you are trying to achive with the pics. Use the IMG button down the bottom of the screen and paste that here.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/P1000164-1.jpg

http://i968.photobucket.com/albums/ae167/rajkovlado/P1000166.jpg

http://i968.photobucket.com/albums/ae167/rajkovlado/P1000165.jpg

And the car....

http://i968.photobucket.com/albums/ae167/rajkovlado/P1000159.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/P1000163-1.jpg

[dado]

is this all i need to keep the 02a with the engine in mk1???http://www.vwwatercooled.com.au/forums/images/imported/2009/12/010a180-1.jpghttp://www.vwwatercooled.com.au/forums/images/imported/2009/12/010A190-1.jpg

[Golf Loon]

Yes, but the gearbox will still be as heavy as your car and you will have to fit the cable shift mechanism too.

Plus the massively long cable clutch will be really heavy and will pull through the bulkhead on a Mk1.

[Preen59]

Yes, but the gearbox will still be as heavy as your car and you will have to fit the cable shift mechanism too.

Plus the massively long cable clutch will be really heavy and will pull through the bulkhead on a Mk1.

I think what Matt is trying to say is "Use an 020 instead". :)

[jayjay]

is that an engine mount to lower the motor?

i cant remember where i saw/read this, but does the bonnet of a golf 1 have the clearance for the 16v abf manifold? because it's a tallblock.

[Preen59]

is that an engine mount to lower the motor?

i cant remember where i saw/read this, but does the bonnet of a golf 1 have the clearance for the 16v abf manifold? because it's a tallblock.

The block is only 10mm taller. Valver had/has a Mk1 with a Seat ABF in it...

[Peter Jones]

is that an engine mount to lower the motor?

i cant remember where i saw/read this, but does the bonnet of a golf 1 have the clearance for the 16v abf manifold? because it's a tallblock.

Nope, that's what's needed to bolt up the 02A Gearbox to the MK1.

Tall blocks fit in Mk1s. I have an 8v tall block in one of mine.

Pete

[dado]

020 31kg
02a 38.5kg
02m 51kg
info from the net.not much weight difference and 020 could not handle any more power and 02a would be good up to 300hp stock.
custom mounts and cable+mechanism around $600

[Preen59]

Actually the 02a is about 25% heavier if you do the maths. 7 or 8 kilos might not "seem" like much but it actually amounts for a fair bit. :)

[dado]

ok i will take but what about benefits
is it worth $600
or if anyone know if there is any cheaper

[dado]

finally started some work on the abf engine today. i remove the p/s pump,a/c compresor,alternator,belts and various brackets etc. in with the new alternator bracket for a test fit and find out that the original alternator can not be used with it. bracket is original vw for abf non a/c. does anyone know what alternator should i look for? http://www.vwwatercooled.com.au/forums/images/imported/2010/03/P1000218-1.jpg (http://s968.photobucket.com/albums/ae167/rajkovlado/?action=view&current=P1000218.jpg)

[peedman]

vagcat.com it to find out if the alternator is different. if u want an alternative u shoulda bought this a/c delete instead:

http://cgi.ebay.com/ebaymotors/95-96-97-98-99-VW-Golf-A-C-Bypass-Delete-Pulley-1999_W0QQcmdZViewItemQQhashZitem25569e30aeQQitemZ1 60366997678QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAcc essories

i bought one and sure its not 100% pretty but it spins straight and u can reuse everything that u already got.

[dado]

i have find it! it is the following:
ABF - Non-A/C Mk3 setup

70 amp non-A/C alternator Spring tensioner
Bosch part number: AL0185X or 0-123-315-001
Worldwide Reman part number: 14356 (price as of 2/6/09 is $119.49)
VW part numbers: 028 903 025 G and 030 903 023 E
Valeo part numbers: 2541821 or 436363 or 439000 or A11VI66
Lucas (LOL) part number: A6785

90 amp non-A/C alternator
Bosch part number: AL0187X or 0-123-320-002
Worldwide Reman part number: 14358 (price as of 2/6/09 is $164.49)
VW part numbers: 028 903 025 P and 030 903 023 F
ACDelco part number: 321-1712
Lucas Part number: A6786
Valeo part numbers: 2541814 or 2541814A or 436443 or 439002 or A13VI123

Belts that might fit a mk3 non-A/C setup:
These are six-rib serpentine belts - that's what the 6pk means. Measurements are in mm)

PROPER belt - Continental 6PK 0894 (this belt has 6 ribs, and it is 894mm long)
other belts:
DAYCO 5060390 (it's 6pk by 0990mm)
DAYCO 0560455 (it's 6pk by 1155mm) and I don't think this is right!
DriveRite 390K6
Gates 6708 or K060388 or K060390
VW part number 999.192.283.50
http://www.vwwatercooled.com.au/forums/images/imported/2010/03/pully2-1.jpg (http://s968.photobucket.com/albums/ae167/rajkovlado/?action=view&current=pully2.jpg)
Notice the spring:
http://www.vwwatercooled.com.au/forums/images/imported/2010/03/spring-1.jpg (http://s968.photobucket.com/albums/ae167/rajkovlado/?action=view&current=spring.jpg)
That's what tensions the alternator.You loosen the pivot bolt,and the 19mm tension bolt,and let the spring tension the alternator,then you just tighten the bolts and roll!:cool:
http://www.vwwatercooled.com.au/forums/images/imported/2010/03/wholebay-1.jpg (http://s968.photobucket.com/albums/ae167/rajkovlado/?action=view&current=wholebay.jpg)

[Preen59]

I like that setup. Thanks for the part numbers. I'm after the same for my 16v. :cool:

[jayjay]

there's actually another way to do it with an existing mk3 bracket, different waterpump pulley and crank pulley with a custom belt. measure twice order once?

i thought pete jones has that on his mk1 race project

[Peter Jones]

i thought pete jones has that on his mk1 race project

Yep, that's right.

There's some good info above that someone should copy across to the belt thread please.

The Serpentine belt thread is here http://www.vwwatercooled.org.au/newforum/upload/showthread.php?t=19887

http://www.vwwatercooled.com.au/forums/images/imported/2008/10/P1310889-1.jpg


Either approach will work. The way I did it leaves the alternator quite high up in the bay which might interfere with the inlet side of things on a 16v. Other issue with my approach is that the tensioner interferes with the chassis rail unless you make a few adjustments.

Mounting it in the low position will be getting close to the front panel work that the radiator sits on. I'm not sure just how close.

I'm thinking of a very different approach for my 16v when I finally get around to it. Something off the back of the block like a compact hot rod alternator.

Got a feeling some of those parts to mount the alternator in the low position are hard to come by here, but might appear on some T4s.

Pete

[jayjay]

I'm not too sure about the clearance on a mk1 with the 16vg60 alternator relocation set up. this basically mounts the alternator to the back of the block where the 16v throttle body of a mk2 would normally be. the issue with this, is that one would require a 16v scirocco inlet manifold with the throttle body coming of the passenger side of the manifold.

[dado]

Small update on this

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_0176-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_0179-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_0178-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_0180-2.jpg

So far engine is out from mk3 and all mounts have been removed and replaced with mk1 mounts.Have decided to keep the 02a gearbox and have bought custom mounts to fit.The driver side mount need some spacer for two bolts as the mount does not sit flash with the engine.I have replaced the hydraulic gearbox mechanism with cable one.Engine is out from the mk1.Things look good just needs a good clean and tidy up-maybe respray.
Looking to buy some good rubber mounts inserts and the alternator to suit the set up. So far the hunt for the alternator has been unsuccessful.Also need to buy vr6 water pump pulley.I will be attacking the mk1 engine bay and trying to sort out all the wiring.

[Jarred]

woot! goodluck

[dado]

woot! goodluck

Thanks Jarred.
done some work . not staff that i was planning to do today but due to missing some tools work got diverted into other area.i installed the cable shifter,replace the fuel tank,rear brake upgrade and new handbrake cable.ordered tt race motor mount kit and try to buy a alternator with no luck.if i don't find alternator by the end of the week i will go for other set up like Peter Jones did with his car
the details for the alternator are
90 amp non-A/C alternator
Bosch part number: AL0187X or 0-123-320-002 if anyone can help?
working on the mk1 is much fun but due to the age of the car thing can go so slow...
I am sure most of you will now that ....If I was a mechanic and get paid to do it would be hard to quote any job on it that is for sure.
Also on the good note there is no immobiliser on the half cut i bought and thats great when it comes down to wiring.
cheers
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_0184-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_0182-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2010/10/IMG_0181-1.jpg

[Water Boy]

Good work mate!

Keen on some pics of that blue cabby in the back ground.

[Peter Jones]

Just spotted the alternator you're after on the BFI site.

ABF Alternator Set-up for ABA (http://store.blackforestindustries.com/abfalseforab.html)

[dado]

Just spotted the alternator you're after on the BFI site.

ABF Alternator Set-up for ABA (http://store.blackforestindustries.com/abfalseforab.html)

great! thanks Peter.

[Golf Loon]

I have a couple of alternators that will work. Come down if you have not sorted it Mik.

[dado]

Massive progress on the car today. With a lot off my cars gone and heaps of parts cleared from my place I finally and up spending some time on the car.
Pictures up 2morrow.

[Preen59]

That's what I like to hear. :D