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Hiya chaps I need some help if anyones knows any information on this subject. Ive just bought a 1.8T engine and gearbox from a 98 golf gti and Im wondering if anyone else has done this before me. The main problem is the engine mountings do these have to be prefabricated or is it possible to use an existing subframe from another VAG Model. Any info would be greatly appreiciated and alll the steps for fitting this engine I will post on this forum as it appears that quite a few people are contemplating this conversion.

LMAO!!!!

the engine mounts are the start of problem mate! I started this conversion thinking it couldnt be that difficult. It fecking is - that difficult my mech 'mate' left me on my own to do it!

The amount of kit you've got from the car will affect how difficult the conversion is. Driveshafts will need cutting (or i was debating getting some Ibiza Cupra ones as these are *supposed* to be shorter. Another couple of problems you will encounter :

- Wiring
- The engine will immobilise itself with the orignal key
- Converting the coil packs the polo's ignition
- Wiring
- battery needs moving (as the filter sits EXACTLY where the battery tray is)
- Ancillary resoviors may need moving
- Slam panel needs modding - and fitting an aftermarket front mount intercooler is a nightmare
- wiring
- Bulkhead will need modding
- Wiring
- It will run well hot with some sort of vents/cold air feeds
- Wiring

Most of the electrical faults can be resolved by a JD Engineering custom ECU (based on a G60 item) - but these have to be imported from a Holland and cost major money (more than i paid for the engine)

You should be able to cut the mounts out of the donor car and weld them into your bay

TBH unless your a skilled mechcanic whose has done an engine conversion before dont bother I dont wish to put you off cause a 20vT Polo would rock (i still want to finish mine) but theres a reason Dubsport quoted me £10,000!!!

hope that helps

Massive respect for this conversion... It's awesome. It's also quite hard.



But Karl told you that already.

To put things into perspective, meet Steven. Steven started his 1.8T conversion a long time ago and I more or less followed his progress. It took the better part of a year to get the car running, doing all the work (or whatever he could) himself.

The result:



As you can see, he managed to get the airfilter (aftermarket) in there, without moving the battery. But the battery is peanuts compared to the rest of the problems you'll encounter.

Wiring:



Some more wiring:



And then some:



And some custom engine mount brackets:

http://www.polo6nf.de/images/umbauten/m ... C00551.JPG

...that you need to weld to the car.

To me, the guy is the automotive equivalent of a Pop Idol. That's some seriously hard work and sometimes I wish I'd done what he did.

If you're serious about this, be prepared to spend quite a bit of money and a lot of time in the garage. I'd say go for it... I'd love to see how it would turn out.

Also wish I had the knowledge/time/money/place/alternate car.

Steven's page:

www.polo6nf.de

(in German)

Right chap cheers for the advice Ive been on the phone to just VW's in Blackburn lancs at the moment they have a 6N2 on the ramps and have quted me a cracking price for the conversion. Theyve quoted me around £700.00 for parts and hes getting back to me on the labour but I recon Its going to be about a grand for the work which will total up to £1700.00. That includes a fully programmable Ecu which will allow me to reain the original clocks. however I bought the engine gearbox wiring loom and
the original ignition barrel and key for £800.00 the engines covered 60K but I'm hoping to strip it all and prepare everything by the end of the month so I can nick the wifes car as the spoilt b***h has ordred a MK5 1.6 golf so I'll be able to break it in for her but either way that engines going in my polo so it'll kick her arse!

Cool plan.

Keep us posted!

(NPI)

Heres what I know so far when planning this engine conversion try and get hold of a 98/99 golf gti engine and gear box as the throtle linkage is cable operated also the inlet ports on the head are bigger allowing higher boost and fuel settings with the help of a chip. The 00 engine onward is throttle by wire meaning more wiring that what is needed.

There are two ways of mounting the engine firstly utilising the original polo top mounts and prefabricating mounts directly onto the engine block however the route that I and taking is the same as what Jabba sport did with their 1.8T Lupo and that is to weld golf mk 4 engine mounts dierctly onto the existing Polo subframe using a jig measured dierectly from the mk 4 golf subframe as the left hand mount is positioned higher that the right hand mount. It is critical to get these measurements correct as the engine has to be at a exact angle compared to the subfame as loss of power will be incured if the angle is not set right.

A front cross member is also going to be made for the front engine mounting as to support the engine fully.

With the engine mounts soon to be sorted next will be the driveshafts. I've heard that Seat Ibiza Cupra drive shafts may fit but I am unsure as the floorpan is the same as the mk4 Polo however the subfame is from a Golf mk3 and the drive shafts may be the incorrect length. The only way around this problem may be to machine new drive shafts to the correct spec but I'll make the dawings available to anyone who requires the information.

with the engine and drive shafts in place the clutch and gearbox linkage shoulnt be too much of a problem as Golf Mk 2 owners who have fitted 1.8 T engines into their cars have opted for the polo gear selector mechanism which fits inside the Mk2 Golf tunnel better than the mk4 unit as it is actually thinner than the mk4 selector.

The battery is going to be relocated into the boot which is fine because I dont have room in my boot for anything usefull as it is crammed full of ICE.

An induction kit will be fitted and hopefully this will be housed in a carbon fibre box with ducting directly form the grill to ensure cold air flow into the engine.

if possible coulld you gets some pics of the build - any help on the mounts and crossmembers would be greatly appriciated!

and lucky you getting a 99 engine! i've got a 00 one (which is why i'm having so many problems). As alex said let us know how you get on as i may sell this engine and get an older one if your conversion goes ok.

If you want some pics go on to the jabbasport website and click on the Icon "jabba goes racing" if you move the curse up to home but not click on it an extended menu comes up then click on "the build" this shows step by step pictures of their audi TT engine fitting in to the lupo which the subframes are almost identical to the MK4 Polo but I will be taking pictures of the build as I go along. I will post any measurements on the forum to help anyone who needs it.

The 1.8 20VT has stopped being produced now and the golf Mk5 will house a new 2.0L turbo engine pushing out around 220 geegees but the engine may be that little bit to big for the polo the way forward is the 1.8T engine as the unit is far lighter than the VR6 and more tunable. Jabbasport recon they and get 350brake from this engine.

see ya later

I believe the 1.8T is still in production for the Seat Ibiza, for instance.

On the drive shafts: Steven had his TT ones cut to the correct length, then rewelded. Worked fine.

Welded drive shafts are an MOT failiure besides I would sooner get them machined to the correct spec. Not sure if Seat are still using the engine but VW are stopping using the 1.8, I presume Audi will as well. Everyone slagged the golf GTI as it was underpowered compared to its rivals.

but what sort of gearbox will u fit un ur project polo?