Most liked posts in thread: My MK2 VW GTI 20V 1.8T Projekt

Thanks, I got back from AMVIV and was able to dedicate some time to this project. The gas pedal was too high so it had to be moved down. I didn't account for the fact that the pedals would be lower after they were connected to the brake and clutch master cylinders. It is in and good now. I am going to get a newly rebuilt trans with a TDI 5th gear and Peloquin LSD in it in a couple of weeks so the engine is still not in. I have just been trying to get all of the wiring run. I also got the MKIV HVAC installed. I need to update this with some pics soon.

 

Here is some of what I have been up to:

I installed the MKIV horns so they just plug into the harness:



Here is the lower wiring harness mounted in the same location as the MKIV using the same mount. I made a template and cut it out and it fits great and will be waterproof



Here you can see the MKIV HVAC mounted:



I messed up and had the painter fill the wrong hole and I also cut the lower post off because I thought it wasn't needed to secure it. Fortunately it is still secured tightly and the hole will be covered by the heat shield. This allows me to run the AC compressor from the MKIV engine, the coolant lines for the heater core, and it is all plug and play with the wiring and dash.

I added some poly inserts to the rear mount so now all of the motor mounts are upgraded:



Here's som close-ups of the polished bits:



I ordered a new rain tray yesterday to cover up all of the wiring and ECU. Here is how it all looks now:





I still need to ground a few wires in there and Here are the wipers installed. I swapped the motor from the MKIV into it so it is plug and play with the harness and will have all of the settings that the MKIV had:



I was getting ready to work on the car today and realized that I hadn't taken care of the new paint in the bay. I pulled everything out that wasn't bolted on and washed, clay barred, hand polished, and waxed it. I am going to buff out the wax tomorrow, but I buffed it off of the firewall and got the MKIV heat shield installed:



It is ugly, but with the turbo there it is necessary. Tomorrow I am going to get inside and start working on the dash and wiring. I still have that steering column to do as well. For the engine, I ordered a set of the Gruvenparts pullies and I have been talking to Eurojet to get a street core, TIP, DV, and coupler to run my upper tube. Once I get the engine in, I'll figure out what to do about the rest of the piping.

 

I buffed up the bay so now it is ready for everything to go back in. I used Prima Mystique to wash, claybarred it all, hand polished it with Prima Finish, and applied Prima Epic which I let sit overnight. Here is the result:



Not much else to look at. I am trying to get all of the wiring run.

 

I got my EBC Redstuff pads today so I put the brakes on:


I still need to order some stainless steel lines and hit the junkyard for new hard lines since they were frozen on and I had to cut them to get them off. I also decided that I needed to stop putting the dash off so I got started on that today:



I only got the template done before my light ran out. I'll try and take lot's of pics of this since I haven't found a MKIV dash swap DIY anywhere. From pictures of swaps I have seen, it looks like the window cranks are not practicle and since i am using the whole MKIV harness, I ordered a set of Spal window regulators and I also got a used sunrof motor from the classifieds to make everything power in the interior. I also ordered the last of th engine goodies that I needed:

Eurojet Turbo Inlet Pipe



Eurojet Frag Grenade Diverter Valve



and I am also getting one of their street intercooler cores and a complete Gruvenparts pully set:

 

You know that grenade is going to be polished too

 

I got a new ABS rain tray from the dealer yesterday. Of course my rain tray has been modified, so I had to do some cutting on this brand new part in order for it to fit:



This really cleans things up. I am going to spray the exposed areas with bed liner and once I get the weather stripping on it is going to look really clean up there. I did some hacking on the dash too, but my Dremel brushes died. The pulleys also got here so I will try and get them on the engine tomorrow.

 

Awe tuning does good stuff .

 

Last week I got my Gruven pulleys in the mail and after putting them on and seeing that billet aluminum next to the dull alternator and tensioner, I decided that some more polishing needed to be done. They were finished today and here is how they turned out:


After this I still need to get the transmission polished. I am going to definitely swap it for a newly rebuilt one with a Peloquin diff and TDI 5th gear. I just need to get it all coordinated with the guy.

 

I have mostly been doing a lot of things that aren't too visible. I added power windows and mirrors, installed a motor for the sunroof, gutted the interior and am now trying to figure out how to sort out all of the wiring. I also got some things back from powder coating:

Headlight and radiator supports



Also a fan shroud from a Corrado that I had modified:



The Corrado radiator has the inlet and outlets on the same side as the MKIV do it will make running the hoses a lot easier. I removed the Corrado belt driven secondary fan and with a little cutting and welding on the fan shroud, I was able to mount the relay controlled secondary fan from the MKIV. It is thicker than the Corrado fan, so I had to space it on the one side so it would clear the radiator. I will wire the pigtails from the primary fan and temp sensor into the MKIV harness and it should function just like it did on the GTI:

 

Yeah the rest of car has a really bad cheap black that was sprayed over an un-prepped red paint. Nothing was removed when it was done so that is why you see the red parts. Of the shiny black parts, only the top of the headlight surround will be visible, so it will be cream and black when the hood is opened. I am doing a two tone with the bay different than the rest similar to this:



except that the outside color is going to be close to this: