Late bay Gti conversion

Discussion in 'Modified Shizzle' started by illzlee, Nov 26, 2017.

  1. So, this is a conversion that has been on the cards for a while.

    I’ve had my bay for 12 years this year, I bought it as it had already been converted to a Diesel engine.

    My spannering skills have got better over the years, and I feel like I need a change from the 1.9td engine (originally from a xantia) that resides in my bus.

    So - to start the tale, I’ll start with a pic of my beauty [​IMG]


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  2. Looking good .:)
     
  3. After looking at alternative engine options and being put off by the cost of Subaru I stumbled across the Facebook group of folks that are converted their t25’s to Gti power using all original diesel parts.

    As my van was converted to a t25 gearbox (not sure why) for the Diesel engine conversion I started looking at costs of the diesel conversion bits.
    Then got a shock! Clearly they are popular as t25’s get fewer and fewer.

    So, found a donor van and decided to break it and recoup some costs.
    Picked this up on Boxing Day 2016[​IMG]


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  4. Managed to sell all the parts off the white van and learned a lot more about how these vans go together by dismantling one.

    Then word got round at work I was turning into steptoe and I was offered this cheap[​IMG]


    So I was now a bit distracted and not anywhere near starting my conversion!


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  5. I’ve now got more than enough diesel parts to start my conversion, but I need a donor...


    The Mk3 golf Gti 8v is the same inline 4 cylinder engine block as the diesels used in the t25 - the AGG code engine is the later unit used in gti’s and produced a healthy 115bhp from the factory. They are still quite a basic engine and relatively tuneable apparently if the 2.0 8v isn’t enough for you.

    So I joined the Mk3 owners club sales page on Facebook, sat in macdonalds with the kids one Saturday afternoon and click open the app to find this advertised locally[​IMG]
    [​IMG][​IMG]

    A 1997 Mk3 golf Gti colour concept limited edition, 107k on the clock.
    Just out of mot, but looked very clean and had been looked after well by many (many) previous owners

    Turned up to view it at basically the local drug dealers house, it all seemed very dodgy but I took a chance as it ran well and the mileage checked out on mot history checker.
    Picked it up for £300 and got it home hoping it wouldn’t explode and strand me in a rough bit of town


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    Merlin Cat likes this.
  6. Thanks to the excellent guide on what parts you need from a donor from the t25 Gti club, the surgery began[​IMG]


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  7. What was invaluable was the wiring diagram/list from the Gti club which turned this
    [​IMG]


    Into this after about 5 hours work
    [​IMG]


    And producing all this waste

    [​IMG]


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    Lardy, nicktuft, Sick Boy and 2 others like this.
  8. Colour concept seats are awesome, heated leather recaros.

    Worth a few bob too.
     
  9. In order to make the i4 engine sit at 50 degree slant you fit the t25 Diesel bellhousing to the 091 gearbox, so time to swap housings over


    [​IMG]


    And I put shafts swapped too as these are a different length
    [​IMG]

    Then with the engine out of the car, a chance to swap cambelt/aux belt/water pump etc...
    [​IMG]


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    Moons and nicktuft like this.
  10. The angled sump retains enough oil depth even at 50 degrees slant, and the mounts give you something upright to bolt to - so all these get used from the diesel t25



    [​IMG]

    [​IMG]


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    Merlin Cat likes this.
  11. As the golf engine is high pressure injection I need something to provide enough fuel or suffer starvation with only a gravity feed tank. (Even though my bay was 2.0 fuel injection originally)


    Using a mk2 golf fuel pump with built in swirl pot seems to do the trick - need to obtain one like this



    [​IMG]


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    Kruger likes this.
  12. So, all this progress was well before summer - so took a last holiday away diesel powered with a jaunt round South Wales taking in volksfest wales.
    A good old fashioned show if anyone fancies it - but of course it hammered down with rain for 2 days out of 3!



    [​IMG]


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  13. Now onto the slow progress section - only really in the last month.

    In she goes under her own steam for a while [​IMG]


    Bumper and towbar removed for slightly easier access

    [​IMG]


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    tonyb, rob.e, Dubs and 2 others like this.
  14. So with bum in the air, I set about getting the old lump out - making not of wiring as I went

    [​IMG]

    After significant swearing

    [​IMG]


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  15. Wiring checks took a lot longer than planned as all additions to the factory loom had been done in the same colour cable.

    [​IMG]

    And I also found out why my towbar wiring had stopped working!

    [​IMG]

    It is probably time to renew the body earth too...

    [​IMG]


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    Merlin Cat likes this.
  16. Once wiring had been disconnected and all coolant hoses, cables etc she was finally free of her diesel heart

    [​IMG]

    [​IMG]


    And gearbox split from engine to make the weight more manageable


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  17. Best thing I did was to make 2 engine skids.
    Rip a sheet of 25mm ply in half lengthways and fit on castors with some old ikea kitchen handles for dragging it about.

    Made life a lot easier!



    [​IMG]


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  18. Aswell as bellhousing change the clutch release arm needed changing from hydraulic to cable - homemade puller made short work of it: once you realise there is a circlip hidden in the oily filth that is!


    [​IMG]


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    Merlin Cat likes this.
  19. After wondering what to do about refurbishing my fuel tank I struck lucky and picked up a cheap ‘shop soiled’ one from c&c at Stanford hall last year.

    So out came the old, as it had been ‘clearanced’ by the last owner with a lump hammer to allow the diesel head to fit

    [​IMG]

    Because it was dented it put up a real fight and required some persuasive intervention from a crowbar

    [​IMG]

    But now it’s out I’m greeted with the vans original colour, and thankfully not a lot of any rust that needs treating

    [​IMG]


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    Merlin Cat and CollyP like this.
  20. Interested in this as I've put a 16v MK3 (ABF) into a friends earleee bay, Using the same T25 parts, Do you have to create space at the tank where distributor sits? - as per the previous conversion installed.
     

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