Golf 2002 - m42 swap

[jakeb]

Another m42 swap under way, on a Golf 2002 this time. This one is for Andy...and will get an e30 5 speed with an electric speedo.

I was able to use the stock e30 driveshaft with this one. I had to make a different mount for the center bearing. I was worried it was going to be bouncy, but with using the angle iron it is rock solid.

Waiting on a couple parts but it is coming along...

On to a few pictures

One completed m42 2002 and another that is a week or less away....

The mounts..

and a jig....

and after a good day of work...all is right in the world.

[skipsfcr]

You ingenious sob! You've got this down to an art. Are you using an E30 intake on that car or using the E36 manifold? I notice you've still got the E36 harness in place. Not a problem of course, just a little obtuse.

[jakeb]

I was hoping to be able to use the e36 intake but it won't fit without moving the engine forward a bunch which I don't want to do. So....e30 intake with e36 harness. I like the e36 harness a little better and it has knock sensors so that is a plus. It just doesn't have the valve in the intake so the map might be a little off but I don't think it will be an issue.

I think the e36 intake would fit if I took the studs out of the head and used bolts because then I would be able to slide the intake down to the head and not have to go over the studs.

I must say I have the swap down now.... I can remember a few years ago people saying it was too hard to even try.

[skipsfcr]

.... I can remember a few years ago people saying it was too hard to even try.

All because ONE guy swapped in the WRONG variant for his application and chronicled it (minimally) on the web!

I took too damn long getting mine together, with good reason. But YOU singlehandedly might make this as commonplace as an M20 or S14 conversion.

[AndyS]

You two made me do it. The 2000ca is so fast/quick compared to the stock M10 with a 38/38.

[schwarz75]

Nice work Jake. Those are sweet engines, and perfect for a 2002.

[M5wanaB]

man you can really crank these out. Any chance you would make me some engine mounts? trans brace? It would take a ton of the guess work out of my swap. Email me if you can. Raw is fine I can get them coated.

[jakeb]

A little more work done today....its pretty hot in the garage but at least it is cooler than being in the sun.

Finished the trans mount, need to pull it off and spray a little paint on it. The driveshaft is fully in and tightened up, very very happy the e30 shaft worked without a hitch.

One hurdle with this swap is how to clear the track rod.... What I do is push the trans up as high as possible, to do this you have to cut the ears on the top of the trans off (these are used to mount the shifter carrier on the e30)

before

after

Then I grind a little off the top middle of the track rod and take a little off the bottom of the trans. The only spot it hits is right in the middle of the trans and when the wheels are straight. The picture looks like a lot has been taken off the trans but it really isn't much at all. There are other ways to do it as well but this is the easiest in my book.

Exhaust down pipe started, its only tacked right now. Tomorrow I will fully weld it, put the O2 sensor in, etc etc. The picture makes it look like the exhaust is really close to the steering, it is actually pretty far away from it.

36" Lokar throttle cable and a little bracket off the transmission...The throw of the stock pedal just about matches the m42 throttle body perfectly.

The m42 wiring, I set it up so the engine harness plugs in just like it was in the donor car. One relay pulls power off the battery and clicks on from the stock coil wire. This way the efi bits are not directly pulling power from the old 2002 wiring. The other relay is for an electric pusher fan up in the nose which is controlled by a thread in temp switch in the radiator.

Wiring is just about sorted...lower manifold is on and all the cooling lines are hooked up. (thanks to blunt for getting the coolant pipe to me so quickly) Radiator is in and mounted...

[jim325]

God that is a beautiful job, you need to write up full instructions and pic's and make offer to members. Would be more than willing to pay you for same. I'm very envious of your endeavor. Thanks jim325 or jim02@cbbmail.com

[Guest Anonymous]

Rail Method!!

looks good! gotta come for that visit i keep promising/threatening ..

[ray_]

Go Jakey go!

Cheers,

Ray

[jakeb]

A little more done this morning...

Fuel system is all hooked up and ready to go....just need to wire the fuel pump (waiting on a pigtail - anyone parting an e30?)

Fully welded the exhaust downpipe and o2 sensor bung.

Installed the speedo sensor and electric speedo

Here is a picture showing how much I take off the track rod, clears with about 1/8" maybe 1/4"

I am waiting on the upper intake manifold and valve cover to come back from the powder coating then it will be running.

[s99]

So do you just not use a shifter carrier? How is the linkage set up?

[skipsfcr]

The later transmissions still have the two bolt bosses like the 2002/E21 4 and 5 speed transmissions so when the later style shifter bracket ears are removed there's still a provision for an '02 type shift platform although it doesn't look like Jake went that route. (not meddling, just speaking from experience)

[jakeb]

skip: I didn't even notice that there are the bosses for the e21 late 02 shifter carrier. That would have worked out even better. Thanks for the info.

The way I have it set up should be fine as well. It is the same way I have it on my 02 and have had no issues for 4k miles.

But it would be more....correct using the late 02 carrier.