Sammo
Club Retro Rides Member
Posts: 1,461 
Club RR Member Number: 103
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Dec 17, 2017 11:22:52 GMT
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Morning  It's been a long time since I actually committed to a proper project. I've got my Mk2 XR2 waiting patiently in my garage to be welded back together but I still haven't built up the enthusiasm to start on it haha. I don't want another year of doing nothing car related and ideally I'd like something (kinda) retro to take to the weekender and the gathering this year I've owned this Mk2 Caddy for a couple of years. It was bought for me to drive around the country when I was Karting so I could sleep in the back of it. It served its purpose for a year very well (apart from a tyre blowing out at 70mph on the M6!) and then got demoted to a moveable storage unit holding all the stuff I couldn't fit in the shed. After covering an entire 100 miles between MOTs I decided to sell it. Unfortunately these vans in petrol flavour aren't really worth anything so it's sat around for quite a while with people offering me £200 quite regularly. I decided a few weeks ago that for the minimal amount it costs to insure I might as well keep it However the 1.6 75hp engine fitted has very much come to the end of its life and doesn't really have any guts anymore. I had a look around at what engines have been fitted to these. Plenty of TDI, 1.8T and VR6 conversions have been done but looking around at the cost of those engines it was going to be out of my budget to buy one. Realistically the 1.8T and TDI were never going to be options anyway which left the now expensive VR6. While looking around at engines I spotted a couple of build threads fitting the VW V5 engine into older cars. I had a look on YouTube and loved the noise these make. Ok, they're not quite as powerful as the VR6 but to be honest anything is going to be better than the wheezy 1.6 that's currently adorning the engine bay. I started scouring eBay and quickly came across a complete V5 conversion from a Mk4 Golf. It wasn't far away and was less than half of what a similar VR6 conversion would cost I spoke to the seller who confirmed he was happy to keep hold of it until I could get a spare day to collect it. I've done some research and can see the engine mount on the drivers side is different to what's in the van (there isn't one in the van basically!) so I've spoken to a friend who builds funny cars for a living and he's agreed that if I slot the engine in on the other mounts and trailer the van to him he'll fabricate one for me After that all I need to do is figure out the wiring differences and voila! Sounds easy haha! I'll leave you all with some pictures of the van looking rather sorry for itself. The bodywork is poor (at best!) but it's actually really solid underneath. It'll get tarted up a little so it's presentable but nothing major.        Hopefully this is of interest to people so I'll keep it updated as I move on with the various tasks ahead I'm also on Instagram if anyone wants to follow me. @parttimecartinkerer. Cheers, Sammo |
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Last Edit: Jan 20, 2019 14:00:27 GMT by Sammo
Follow Me On Instagram - @parttimecartinkerer
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Dec 17, 2017 11:33:39 GMT
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Bookmarked this will be interesting.
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Sammo
Club Retro Rides Member
Posts: 1,461
Club RR Member Number: 103
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Dec 17, 2017 11:53:25 GMT
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The van was relegated to the road a while ago and hasn't moved for at least six months. I took the battery off and charged it the other day and then popped it back on the van this morning. It fired straight up as though it's something it did every day (it may of smoked out the entire road with oil smoke when it did this!). I took a couple of pictures to send to my mate so he can see the current engine mounts and he already has pictures of the mounts on the engine itself so he has an idea of what he's got to do.    |
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Follow Me On Instagram - @parttimecartinkerer
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andy-v
Part of things
i like cookies :D
Posts: 358
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Dec 17, 2017 12:25:03 GMT
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also bookmarked  |
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Sammo
Club Retro Rides Member
Posts: 1,461
Club RR Member Number: 103
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Dec 17, 2017 12:44:50 GMT
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Oh and so we all know what's going in. This is the donor engine  |
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Follow Me On Instagram - @parttimecartinkerer
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Sammo
Club Retro Rides Member
Posts: 1,461
Club RR Member Number: 103
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Dec 17, 2017 14:02:39 GMT
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If you need any help feel free to ask, I've done a few random engines into caddy's now. I converted my most recent one to pd130! If you get stuck with the loom let me know, happy to help with that. The only annoying thing is the routing of the caddy loom! All the way under the dash, so that has to come out. Nightmare   I may very well take you up on that offer, thanks I've only ever dealt with much older stuff with very few electrics. This will be the first time I've swapped from a basic SPI engine to an all singing all dancing MPI, extra cylinder, never made to fit this engine. |
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Follow Me On Instagram - @parttimecartinkerer
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pegwie
Part of things
Posts: 95
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Dec 17, 2017 14:15:55 GMT
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The great thing about mk2 caddys, is that they're still on CE2 electrics, so same as later mk2 golfs, mk3's etc. Much simpler than newer vag cars. Literally just need MK3 vr6 fuel pump, mk3 golf gti clocks, a tacho converter (for the 5 cyl rpm signal), mk3 mounts (and gearbox, however the vr5 gearbox can be used, you just need to get the correct 100mm driveshaft flanges. Make sure they're same bolt in type if using that. Alternatively mk3 Vr6 02a gearbox mounts up. Use mk3 single mass flywheel and vr6 clutch if so. Along with mk3 starter.) Mount up the 02j shifter from the donor car, lovely shifting feel in comparison to the sloppy 02a setup. Upgrade your hubs/brakes to 256mm hubs off a tdi/d if you haven't got them already, as not 100% sure if your current driveshafts are 100mm inner cv's or not. these can then have early mk3 Vr6 caliper carriers attached, so you can run 280mm discs . Engine wise, you can bin off all the emissions curse word, SIA etc. It's a great conversion. Will sound like an audi quattro! Edit: A thing to bare in mind if you are going to use the vr5's gearbox, the gearing is wrong for the size of wheels your caddy will be running. As it's geared for Mk4 platform cars with 18's. So you would top out at around 120! Not great for motorway cruising as it would be revving high, but great for trackdays....depends what you intend to use it for. Otherwise go with the Mk3 vr6 box. Suited to 15's etc. |
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Last Edit: Dec 17, 2017 14:20:06 GMT by pegwie
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Sammo
Club Retro Rides Member
Posts: 1,461
Club RR Member Number: 103
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Dec 17, 2017 14:31:21 GMT
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The great thing about mk2 caddys, is that they're still on CE2 electrics, so same as later mk2 golfs, mk3's etc. Much simpler than newer vag cars. Literally just need MK3 vr6 fuel pump, mk3 golf gti clocks, a tacho converter (for the 5 cyl rpm signal), mk3 mounts (and gearbox, however the vr5 gearbox can be used, you just need to get the correct 100mm driveshaft flanges. Make sure they're same bolt in type if using that. Alternatively mk3 Vr6 02a gearbox mounts up. Use mk3 single mass flywheel and vr6 clutch if so. Along with mk3 starter.) Mount up the 02j shifter from the donor car, lovely shifting feel in comparison to the sloppy 02a setup. Upgrade your hubs/brakes to 256mm hubs off a tdi/d if you haven't got them already, as not 100% sure if your current driveshafts are 100mm inner cv's or not. these can then have early mk3 Vr6 caliper carriers attached, so you can run 280mm discs . Engine wise, you can bin off all the emissions curse word, SIA etc. It's a great conversion. Will sound like an audi quattro! Edit: A thing to bare in mind if you are going to use the vr5's gearbox, the gearing is wrong for the size of wheels your caddy will be running. As it's geared for Mk4 platform cars with 18's. So you would top out at around 120! Not great for motorway cruising as it would be revving high, but great for trackdays....depends what you intend to use it for. Otherwise go with the Mk3 vr6 box. Suited to 15's etc. From what I can see of the engine mounts the VR5 doesn't have a rear mount that bolts to the subframe like the Caddy. It has a side mount instead which bolts to the chassis leg. That's why I'm getting something fabbed up onto the chassis leg. Yeh I'd heard from someone else that the standard VR5 box is no good for 15's. I'm gonna keep an eye out for a VR6 box and use that instead. |
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Follow Me On Instagram - @parttimecartinkerer
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Dec 17, 2017 14:35:30 GMT
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that so needs to stay visually exactly the same |
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Sammo
Club Retro Rides Member
Posts: 1,461
Club RR Member Number: 103
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Dec 17, 2017 17:09:26 GMT
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With some searching today I've managed to find a VR6 gearbox with a diesel 5th gear for motorway cruising and also a flywheel |
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Follow Me On Instagram - @parttimecartinkerer
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dubwarrior2
Part of things
"Open up, its the filth"
Posts: 576
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Dec 17, 2017 17:20:32 GMT
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I had a v5 golf. Too be honest it was amazing. A great smooth engine with scope for bags of tuning.
Mine was only the 150 option but my brother had the 170 version on his beetle which was rapid.
They can be had pretty cheaply too.
Usual things to watch for timing chains and tensioners.
Fair play for using an engine a bit different from the norm.
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Sammo
Club Retro Rides Member
Posts: 1,461
Club RR Member Number: 103
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Dec 17, 2017 17:32:15 GMT
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I had a v5 golf. Too be honest it was amazing. A great smooth engine with scope for bags of tuning. Mine was only the 150 option but my brother had the 170 version on his beetle which was rapid. They can be had pretty cheaply too. Usual things to watch for timing chains and tensioners. Fair play for using an engine a bit different from the norm. This is the 170hp engine so should shift well once it's done |
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Follow Me On Instagram - @parttimecartinkerer
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Sammo
Club Retro Rides Member
Posts: 1,461
Club RR Member Number: 103
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Dec 17, 2017 19:19:37 GMT
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With some searching today I've managed to find a VR6 gearbox with a diesel 5th gear for motorway cruising and also a flywheel I was going to collect this after dropping my Daughter off this evening but I have it on good authority that the M25 is solid from where I get on and at least halfway to where I get off! So I'm gonna try next Saturday instead! |
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Follow Me On Instagram - @parttimecartinkerer
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village
Part of things
Always carries a toolbox. Because Volkswagen.......
Posts: 567
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Dec 19, 2017 16:26:52 GMT
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If you need conversion parts, check out www.retrofication.co.uk/ where they have bespoke bits for VR6 and VR5 conversions into Caddys, plus a load of Caddy tuning bits |
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"The White Van is strong with this one...."
Chris "Chesney" Allen 1976-2005 RIP
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Sammo
Club Retro Rides Member
Posts: 1,461
Club RR Member Number: 103
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Dec 19, 2017 18:41:10 GMT
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If you need conversion parts, check out www.retrofication.co.uk/ where they have bespoke bits for VR6 and VR5 conversions into Caddys, plus a load of Caddy tuning bits Already been checking it out I'm gonna be using a VR6 gearbox so that mount will be the same as what's fitted to the Caddy already. The rear (drivers) mount is going to have to be custom made as it's totally different to a VR6 engine in that respect. However Retrofication are going to come in handy for flipping the beam for me. I've been chatting to one of the technicians at work today regarding the wiring and between us we realised that I'm gonna have to change the throttle pedal in the van to a drive by wire pedal to replace the cable one that it's got! He could see I was starting to get scared by all this wiring talk and has agreed that if I can get wiring diagrams for both engines and cars then he will sort most of it out for me |
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Follow Me On Instagram - @parttimecartinkerer
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Dec 19, 2017 20:25:39 GMT
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If you need conversion parts, check out www.retrofication.co.uk/ where they have bespoke bits for VR6 and VR5 conversions into Caddys, plus a load of Caddy tuning bits Already been checking it out I'm gonna be using a VR6 gearbox so that mount will be the same as what's fitted to the Caddy already. The rear (drivers) mount is going to have to be custom made as it's totally different to a VR6 engine in that respect. However Retrofication are going to come in handy for flipping the beam for me. I've been chatting to one of the technicians at work today regarding the wiring and between us we realised that I'm gonna have to change the throttle pedal in the van to a drive by wire pedal to replace the cable one that it's got! He could see I was starting to get scared by all this wiring talk and has agreed that if I can get wiring diagrams for both engines and cars then he will sort most of it out for me Wiring does seem scary at first, however it really isn't that hard. I've just converted my MK2 Scirocco to AUQ 1.8t (180bhp), and also fitted the drive by wire pedal from the Leon Cupra donor car. In all I think I needed the splice about 8 wires from the Mk2 loom to the Leon loom. The rest of it is all engine/ecu side of things that never needed to change! |
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Sammo
Club Retro Rides Member
Posts: 1,461
Club RR Member Number: 103
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Dec 20, 2017 17:43:06 GMT
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Already been checking it out I'm gonna be using a VR6 gearbox so that mount will be the same as what's fitted to the Caddy already. The rear (drivers) mount is going to have to be custom made as it's totally different to a VR6 engine in that respect. However Retrofication are going to come in handy for flipping the beam for me. I've been chatting to one of the technicians at work today regarding the wiring and between us we realised that I'm gonna have to change the throttle pedal in the van to a drive by wire pedal to replace the cable one that it's got! He could see I was starting to get scared by all this wiring talk and has agreed that if I can get wiring diagrams for both engines and cars then he will sort most of it out for me Wiring does seem scary at first, however it really isn't that hard. I've just converted my MK2 Scirocco to AUQ 1.8t (180bhp), and also fitted the drive by wire pedal from the Leon Cupra donor car. In all I think I needed the splice about 8 wires from the Mk2 loom to the Leon loom. The rest of it is all engine/ecu side of things that never needed to change! Yeh a couple of people have mentioned how easy it probably is. The thing is I wouldn't know where to start. I've never even tried having a go with wiring. Give me something mechanical and I can work with it. |
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Follow Me On Instagram - @parttimecartinkerer
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adi
Posted a lot
Posts: 1,426
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Dec 20, 2017 18:11:33 GMT
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I’ve not long got my mk2 golf 1.8t running, just to run the engine I literally joined about 5 wires! Making the the rest work took about another 10 i think. I’m guessing this has a cable clutch? So you’ll need a mk3 16v/vr pedal box for the clutch hydraulics and to make holes in the bulkhead too.
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Sammo
Club Retro Rides Member
Posts: 1,461
Club RR Member Number: 103
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Dec 22, 2017 17:32:34 GMT
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Managed to pick up a set of VR6 front brake calipers on eBay today. Absolute bargain too! Also, last Christmas I was given a load of Demon Tweeks vouchers so I used them to buy a pair of 280mm brake discs and a set of braided hoses |
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Follow Me On Instagram - @parttimecartinkerer
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