Engine Conversion - 20VT Conversion Parts List (AGU Specific)

May 09, 2020, 12:53:58 PM

Thanks to cupracraig.

So, it took me a good while crawling through various forums to actually find a comprehensive parts list for the conversion. Hopefully this will save someone the time it took me to find a complete list of parts. There are some good experts on this within the forum, please add any comments so that i can update the list / edit where required.

Disclaimer - This is a list compiled on my reading of the subject - As i am only about 1/4 of the way into the project, this list is subject to change and as such should only be used as a guide, your own reading around the subject is essential if you are looking to undertake such a conversion.

Brakes / Drive
S2 Calipers/G60 Calipers
Carriers
Discs (280 mm, you will need 25mm thick ones for S2 brakes and some machining)
16v Hubs
ball joints (not essential)
track rods (not essential)
track rod ends (not essential)
braided hoses (not essential)
Brake pads
brake servo
brake master cylinder and res

Mounts and Bushes
G60 engine mounts
subframe (not essential)
crossmember (not essential)
crossmember supports (not essential)
wishbones (not essential)
front subframe polybushes (not essential)
wishbone front polybush (not essential)
wishbone rear polybush g60 20mm (not essential)
rear beam polybush kit (not essential)
front ARB polybush kit (not essential)

Exhaust
2.5" downpipe spcific to K03/s turbo - a 3" is generally required for K04
2.5" system

Engine & cooling & Drive
Complete 20v engine, all ancillaries, ECU and wiring to match
02J Gearbox
Gear shifter and cables to match gearbox
100mm driveshaft cups
hydraulic clutch and pipework (Corrado is most common)
pipework
12v slimline fan
intercooler
catch tank (not essential)
dump valve (not essential)
shallow sump (not essential)
ECU - deimmobilised
Loom - spliced (RubJonny is your man for this)
small aux belt for air con delete
g60 radiator - inlet and outlet are in a better location to suit the 20v block
Map sensor relocation tube (MADE BY FORGE)
Silicone TIP
Good quality cone air filter, i.e. RamAir
Assorted silicone hoses an Jubilee and Mikkalor clamps for pipework
VR6 clutch from Sachs / LUK / etc with 02a lightened flywheel + Bolts

Good to Have/Service items
Cambelt kit plus hydraulic tensioner, i.e. Gates kit is well priced and OEM quality
5W30 oil and proper oil filter i.e. VW / Mahle / Mann
Inlet, exhaust, throttle body and turbo gaskets
Assorted silicone hoses an Jubilee and Mikkalor clamps for pipework
Inlet, exhaust, throttle body and turbo gaskets
induction kit

As i mentioned, this is a work in progress and i will add to it as i go along, but i believe this is a good list to get you started on your journey.

thanks

Craig

So the radiator options are now open to debate.

I am considering a Corrado VR6 or a G60 rad,

G60: http://www.radiatorshop.net/products/volkswagen-golf-ii-jetta-18-i--16v-g-60-ralley

Vr6 Rad: http://www.ebay.co.uk/itm/VW-Corrado-2-9i-VR6-92-95-EIS-Car-Engine-Cooling-Radiator-Rad-OE-Quality-/291411090203?fits=Model%3ACorrado&hash=item43d9745b1b:g:RTAAAOSwB4NW1FGN

also going to use this clutch and flywheel combination:

http://www.ebay.co.uk/itm/VW-VOLKSWAGEN-GOLF-1-8T-VR6-LUK-CLUTCH-KIT-AND-G60-FLYWHEEL-WITH-BOLTS-/361437896700?hash=item5427609ffc:m:mQDiaqAYjeO_6ca48oH9kOw

Re: Engine Conversion - 20VT Conversion Parts List (AGU Specific)

Reply #1 – May 09, 2020, 12:54:11 PM

Quote from: FinalD

You can also fit the diesel rad which is longer than a normal one and iirc longer than a G60 one (or maybe the same) but without there price tag.

yeah the GTD one is much longer @ 742mm long from what i can see.

the benefir of the G60 one is that the hoses go in on the opposite side to the normal GTI ones, so less pipework in that tight area between the rad and engine

http://www.radiatorshop.net/products/volkswagen-golf-ii-jetta-18-i--16v-g-60-ralley

Re: Engine Conversion - 20VT Conversion Parts List (AGU Specific)

Reply #2 – November 22, 2020, 12:40:49 AM

Also worth noting you can use a petrol Mk3 tank, youll need longer bolts for the straps and to make some spacers to bolt it all in, then you can use the Mk4 in tank pump.
You need to remove the Mk3 pump mount. It will be all brittle any how so breaks up easily then you can fit the Mk4 pump straight it.

No more rusty mk2 pump thats 20 plus years old and bearly makes the correct pressure, for a 20VT engine.

Mk4 pumps are common to the petrol VAG range and are all the same sub two litre cars, so cheap as chips.