Mk2 1.6 TD engine into Mk1 Cabriolet

**sparkie** · 29-09-2011, 12:56 PM

Hi everyone, just starting to put together the above conversion. I have a 1.6 TD and 5 speed gearbox from a Mk2 Golf, but I have no idea of the history of the engine except that 'it's a go-er", and apart from basic car maintenance I am a bit of a newbie. What would anyone recommend I do to the engine in the way of servicing and maintenance before I drop it into the cabriolet? Also, anyone got any recommendation about what radiator to put in - will the Mk1 petrol in there already be fine, it's got air con!!!! is that an issue? I need an alternator and starter for the engine, are they the same as a Mk1 diesel or petrol engine? There are a few (only a few thankfully) electrical connections on the Mk2 engine, what are they? I reckon the electrical connections using the petrol loom are going to be the hardest. There's one on the water system (temperature sender?) one on the injector pump, etc - maybe pictures would help. The clutch is still on the engine, and the gearbox is lying around the corner of the shed, what should I do to either while I can easily get to them? Anything else while the engine is on the lift? Should I bolt up the gearbox to the engine before dropping it into the car?? Should I paint the engine or any covers? Any help appreciated, would this better more suitable in the Mk1 forum?

**gldgti** · 03-10-2011, 06:28 PM

Hey mate,
The injector pump is pretty important - if it has been stored with the fuel lines plugged up tight then its probably OK but if not it might give you problems when you go to start the engine.

I would put a set of new glow plugs in it for the sake of $80 from a local supplier it might save you an afternoon of headaches wit that "first start".

I would also remove the oil lines from the turbo, and clean them and make sure they are OK. I would probably also pull the sump off and ensure that its pretty clean in there - that the old engine oil hasnt gunked up etc. If it has, i'd recommend putting hte engine on a stand (if its not already) and doing a full strip down/clean/reassemble. My TD cabrio thread in the mk1 section has some pics of hte work i've had to do it that regard.