re: ABF GTI 16V into vw bay camper

[sharpmark]

Hi,

Is anyone else stupid enough to try this, as I am in the middle of the conversion and wondering, is this possible!

Previously this bay was running an 8V gti lump with a type 25 diesel 4 speed box/bellhousing. The plan is to fit the 2.0 16v ABF (from a 94 GTi) complete with CE2/CE3 fusebox from the golf to run the engine.

Ques 1 - Distributor cap is hitting rear fuel tank bulk head, any ideas or suggestions to sort this or do i just cut the bulk head and put a big dent in the fuel tank with a hammer? looking for about 3 inches.

Ques 2 - Using type 25 engine mounts, near side fits but offside does not, any suggestions to alternatives or do i need to make one?

Ques 3 - I've been using a type 25 sump, although it sits over at 50ish degrees as the previous engine did, are there any disadvantages to running the standard golf sump - was thinking of adjusting the oil pickup to suit. as im not sure if the type 25 sump will fit.

So a few questions - would really like to know if theres any others with the same conversion.

Any help would be great cos Im in the middle of this and stressing abit.

cheers

mark

[beetleseb]

Have you got the dizzy hole in the case, like your old 2e?

Moving it to there has been suggested before, you'll need to make a blank for the old hole though

Good luck

Seb
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[Bugsy_malone 666]

essentially from what I understand it should be a walk in the park apart from the distributor.

you use the oil pump/pickup/sump from the T25 diesel, the engine mounts and it should bolt in, you have to do this so you have an oil filler and so you can actually hold any oil, thats why there is a huge big wedge allowing there to be the required gallon of oil but no have the crank lashing away in it. What I have noticed on my TD conversion I'm doing is that the engine mount on the drivers side (where the oil filter is) wont fit the same as on the previous diesel I had in my van because the oil cooler needs turning to clear the engine mount, the passenger side should just be ok, I had to very mildly clear the exhaust manifold/downpipe to fit, but if its been running a GTi motor before I would expect it to be ok.

with the distributor, I have a 2litre 8v, with a 16v head and that gives you a hole in the block to fit a dizzy, however I am fitting that in my beetle and the head majorly sticks through the firewall as the head has about a 2-3" overlap, I get the feeling you may have to take the bays firewall out and alter the tank a bit more professionally than a hammer, although you wont know till you have the engine butted up against it.
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[kruger]

Just an update to say Mark's bus is now running and back on the road,

I was the lucky one given the challenge of converting it, and just wanted to post a couple of points for reference,

The bus a 71 bay, previously ran a rough running mk1 golf gti engine, on whats assumed to be T25 mounts, T25 diesel gearbox and belhousing, and a radiator from an unknown Jag mounted underneath. A real mess of a job to work with thanks to the previous owners cost cutting and bodging ingenuity

Had a few headaches with putting this in and no doubt there may be other and better ways of doing it, but heres the main points to note:

The chassis legs in the back of the van had previously been partially reconstructed with 40x40 box section to (I assume) accomodate the T25 mounts (I'm unsure what a standard bay engine bay should look like) whilst I was there, rust was removed and new metal welded where necessary and the nearside rear engine valance mounting was replaced with a smaller bracket to make engine removal/installation easier,

Trial fitting the engine revealed the distributor would foul the fuel tank bulkhead, the bulkhead panel was cut and boxed to allow the distributor to retain its original position, the fuel tank behind needed to be modified by way of a large hammer to accomodate the recess now formed in the bulkhead panel, a bit extreme but it works!

The offside T25 engine mount does not fit the ABF block, an offside mount was made up from some plate and 40x40 box section, the thermostat housing from the original golf engine was used, as this exits at 45 degrees and was needed for clearance (original ABF exits at 90 degrees)

Gearbox mounting had previously been taken care of.

Cooling system, Radiator was left unchanged, additionally the van also runs 2 vw polo heater matrixs to heat the inside of the van

The engine has been installed with the complete fusebox and ECU wiring loom from the mk3 golf, fusebox installed beneath rock and roll bed, ECU installed in engine bay on offside wheelarch.

Fuel swirl pot installed inside engine bay and is supplied by a lifter pump, a return line was also fitted from swirl pot to the top of the fuel tank.

Exhaust heatshield trimmed to clear engine/exhaust mount, Exhaust fabricated from mixture of new stainless bends, bits of mk3 golf and a T25 silencer.

Things still to do,
Check if the T25 sump will fit - it seems to look like it wont, fit T25 oil pickup if sump fits,
Fabricate some ducting to direct air to radiator underneath,
Sort oil pressure and temperature gauges,
Find a better exhaust silencer,
Check if diagnostic socket works
Plumb in the nitrous?

Think thats about it, so heres a couple of poor pics!

[ElusiveStranger]

Nice

Get rid of that sh###y fuel hose though! It perishes from the inside, the first you'll know is when you see (or smell) petrol leaking out. It might be too late by then.

God knows how people are still allowed to sell that stuff - It's not suitable for unleaded!

Pop down to your local Unipart dealers and get double walled Fuel Injection hose.
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