This is my project thread from another forum. To summarise, it is a 1.4 TDCi > 1.6 TDCi engine swap, which also ivolves:

* Installing ABS

* Installing a facelift dashboard

* Swapping entire interior loom

Right now I have my ZS I can really start messing about with my old MK6 which I saved. The 1.4 was running 110hp and 210ft/lb with a heavy remap and intercooler. Problems are:

1) Poor performance (possible valve+piston contact /ever so slightly/)

2) Poor mpg (before/after the slippage of the belt, average around 300MAX miles to a tank instead of 400-500)

3) Mad oil leaks (before/after slippage of belt)

4) Messy engine bay

I have also sourced my 18's back (currently on my Mk7). Here is how it looked in its day.

So when it's all up and running, with some minor bodywork, it will be riding on 18's with either Brembos or Mondeos.

So it begins...

Access pls.

Bonnet off and placed on roof.

Gearbox covered in oil (my main gripe, I can deal with performance as the intercooler kinda negates it)

More grime and crap

Moreeeee! grime and crap

Remove rad/front assembly

Battery/tray all other bits removed

Exhaust, alternator, manifold, power steering, aux belt etc gone.

Bingo bango!

Wasn't anywhere NEAR as hard as i'd imagined. Mechanic is I am me thinks.

New donor car ^

1.6 style climate. It has powerfolds, auto wipers and headlights as well as one touch down drivers window, i've just gained ABS, aircon, 90bhp (150 when I'm finished), new gearbox/clutch/flywheel factory plugs and new door looms, and more for less than 2 grand.

ANDDDD

If anyone remembers my oil leak. Guess what it was?

Gearbox. The absolute numpty who had fitted my new clutch didn't torque it up to spec, and thats where it was dripping from. Livid.

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Can't wait to get this car back on the road!!!

Today:

Removing dashboard

Received new dashboard (cheers mark, although the numpty forgot my engine mount [waits for mark to blame his staff :P])

Removed dash support - in the process broke both outer covers near the wing mirrors. Hopefully I can remove the ones from the donor car cleanly

The gearbox in the donor car fixed itself??? Im guessing because the hydraulics were ran dry, the 2 weeks I was on holiday let the clutch fully disengage? who knows.

Removed most of the interior wiring loom. Just about to have a bash and remove the heatermatrix - my god this thing is HUGEEEE

Pics

Wooo

Wiring loom transferred, dashboard installed

Everything wired in, just need to swap rear door looms and locks (I THINK the donor car has deadlocks, how do you tell?), and front looms, interior light 'loom' to account for auto wipers and headlights and finally boot loom.

Doubled up all the sound deadening with madmax and two * the OEM stuff.

WOOO PIKEY ENGINE SWAP FTW

All in and working great, fuel pump works, drivers door/immobiliser/power folds/heater matrix all works. No AC as I didnt wanna pay £400 for the pipes just yet, exhaust in, just little niggly bits now.

If anyone can tell me how the washer jets route on this I would be very grateful!

Or tell me what this is?

Also very grateful.

AND Finally

What gearbox oil and how much?? Also where do I fill the gearbox??

Wow looking very nice!

Do you have to change the engine loom too if you upgrade to the facelift dash or is it just interior loom/fusebox/gem unit!

Also how the hell u got auto wiper ect? Where are the sensors for tht?

And that sensor is the radiator resistor sits next to the rad if I'm right!

Cheers

Dwain p

I changed the entire engine (1.4 > 1.6 TDCi) so had a new engine loom anyway (required anyway because the 1.6 TDCi uses an electric power steering pump)

Pikey engine crane

The auto wipe/lights are already on the loom as the donor car I used was a relatively top spec style climate, so I now have powerfolds etc.

Engine is all bolted in nice and tight, still need to get:

Complete front panel with rads/temp sensors

Intercooler

Rear hubs with ABS (front ABS is fitted and working)

Fix electric power steering (nothing working, slight whine, think it may be a dodgy ground)

Pics resized, lol

That first picture looks absolutely evil.

Really nice car, but not over the top.