Greetings!!

I embarked on this project 1.8T swap on a 6n2 polo... Going to share this project along the way.

Engines removal

Edited 23 September, 2025Sep 23 by strobe

Components painting

Intake

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Starter motor

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Power steering pump

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Throttle body

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Edited 1 October, 2025Oct 1 by strobe

You should be posting this in the build thread section https://www.clubpolo.co.uk/forum/49-mk5-polo/

Maybe one of the mods can move it for you

Going to post engines removal again, imgur has failed and I can't edit the post...

Engines removal

Arriving of the donor car

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Removal of the 1.8T

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Removing the 1.0l mpi

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Sending donor car to scrap

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Edited 1 October, 2025Oct 1 by strobe

Wire harness

Staying with the harness set for the ecu essencials and ecu peripherals

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Stripping

Separating the breaker circuit and alot of the interior conections.

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Engine mounts

Got the engine mounts from a seller on ebay. Gearbox mount came with the wrong dimensions so I had to take some material out for it to fit. Lower mount is also not looking good, I think it's also wrong, seller told me he doesn't see a problem, but it's there, you can see the dogbone mount is not aligned. I'll have to maybe get a spacer or something for it.

Side mount

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Gearbox mount

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Lower mount

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Engine in place

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Removing Polo's wiring

Removing polo's ECU essencials and ecu peripherals. Also removing fused protected power and a set of +5VDC and GNDs that power engine sensors.

ECU peripherals

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ECU essencials

This was paired with my speeduino, so I had to remove both.

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Fused protected

This cables go to the inside of the car some are fused others not. VSS (vehicle speed sensor) is here. Injectors +12VDC fused cable is here. A spare +12VDC is also here and ignition protection, also +12VDC. A good set of +5VDC and GNDs are here also, all going to be inhibited.

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Removing Polo's wiring (more photos)

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Clutch Pedal

I decided to use the clutch pedal from the donor car. I have to take the center trim off to gain access. Luckily the polo bring already two bolt mounts that align with the donor's clutch pedal, from the golf 4 and the holes made for the oil fitting from the pedal cylinder. I only have to figure the top mount. Either I cut the pedal or I cut the firewall. I haven't decided. I ordered the adapters for the oil lines. And I still have to order and mount the reservoir.

Center trim removal

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Clutch pedal mounts

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Top Mount that need to be solved

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Fittings

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Mounting the intercooler

Position

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Cutting the shock bar

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Cutting

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Fittings for the clutch pedal and clutch piston, still need to make the hose and buy the reservoir

Powersteering hose .had to purchase a new bolt old one was to short because of the new banjo

Work on the hoses
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Plan was to order edpm hose for water and some air system and nbr hose for a little end of the power steering suppply hose which has a good oem routing all until the end where it meets the pump.

Passing the harness!
Had to remove the pins from the connector