20V Hybrid - How To

[Issam Abed]

If anyone is interested I have a few of the 90* distributor caps.

Guys,
It took a long time for me to complile this information in a clear and concise form for all to read. Sending me a PM asking me to explain to you what is allready very clear will only get you referred back to this thread. If you can not understand what is going on in the 1st post of this thread then maybe the task at hand is too much for you currently and you should seek help before continuing. If a portion of this thread is unclear , tell me where it is unclear and I will do my best to expand on it.

[mk 2.5 fatman]

Will this swap work with digi II? How critical is it to not have a obd I Aba block? How much for a 90 degree cap?

[Issam Abed]

Will this swap work with digi II? How critical is it to not have a obd I Aba block? How much for a 90 degree cap?

1. Yes but I wont recommend it considering what Digi-II came standard with. Highly recommend a cheap standalone at that point.
2. ABA block is the most desired VW827 block available. You can use whichever you wish though
3. $25

[mk 2.5 fatman]

1. Yes but I wont recommend it considering what Digi-II came standard with. Highly recommend a cheap standalone at that point.

Which standalone would you recommend? It's going in a mk2

[Prof315]

Which standalone would you recommend? It's going in a mk2

megasquirt

[4cedboost]

does anyone make a custom piston for a 144mm rod for on an 8v setup? turbocharging my PG block and using an AEG head from a mkIV 2.0

[Issam Abed]

does anyone make a custom piston for a 144mm rod for on an 8v setup? turbocharging my PG block and using an AEG head from a mkIV 2.0

What crankshaft? 86.4mm or 92.8mm?
we make custom pistons for all different applications.

[Roman5400]

What if I have an AZG block? Does all the AEG stuff apply still?

[Issam Abed]

What if I have an AZG block? Does all the AEG stuff apply still?

Yes

[fox-16v]

Alright ppl I am bringing this back from the dead. I want to build a 20v/lysholm. There is no real rush on building this HOWEVER with so many ways of doing this listed in this thread can someone please make a down and dirty parts list for me to acquire everything. I will use/already have a PG/PL/ and can get a ABA block. I would use the AEB cylinder head. Also, pictures are dead for drilling the new oil passage required for the new cylinder head as well as the guide to deal with the cam chain tensioner inside the AEB head.

I will also do this using the stock digi 1 management coupled with a sns chip. So just a basic list for me to get the motor straight would be very helpful. I can figure out manifolds/accessories etc.

[Issam Abed]

I will also do this using the stock digi 1 management coupled with a sns chip.

Forget this completely. The G60 engine comes in chassis's over 20 years old...get standalone

[fox-16v]

Well like I said I'm in no rush. I just have a large abundance of random vw parts from all walks of life and would like to build something unique.

[dielynton]

Hi good day all

just a quick one

why cant the normal 8v pulleys work on the 20v setup?

As far as i know the cam and dist also turns 2-1

[Issam Abed]

Hi good day all

just a quick one

why cant the normal 8v pulleys work on the 20v setup?

As far as i know the cam and dist also turns 2-1

Finding 8V timing belts for custom lengths are a bit hard because the pitch is extremely specific. Also the 20V gears/pulleys are 25mm wide.

[1999.5GTIVR6]

building a DD and have been planning it for months now, was planning on swapping blocks and upgrading rods and pistons.

came on here to see if anyone has used a TDI crank in an AEG hoping to see how easy it would be to make a 2.1 or 2.2L.

then i hear about this oil squirter issue, i thought the AEG had oil squirters. i just read that pete from IE doesnt reccomend the swap because the lack of the squirters.
what are people doing about this ? anything ? what happens if i use the aeg block with out them.

GT3076 around 28 PSI. (High RPM - 9k)
or would i use a AVH, AZG, BGD block, they had oil squirters right ?
i need it to be somewhat realiable

[Issam Abed]

building a DD and have been planning it for months now, was planning on swapping blocks and upgrading rods and pistons.

came on here to see if anyone has used a TDI crank in an AEG hoping to see how easy it would be to make a 2.1 or 2.2L.

then i hear about this oil squirter issue, i thought the AEG had oil squirters. i just read that pete from IE doesnt reccomend the swap because the lack of the squirters.
what are people doing about this ? anything ? what happens if i use the aeg block with out them.

GT3076 around 28 PSI. (High RPM - 9k)
or would i use a AVH, AZG, BGD block, they had oil squirters right ?
i need it to be somewhat realiable

Do you have a 1.8T block?

[1999.5GTIVR6]

Do you have a 1.8T block?

yeah, its going into a 2002 awp car

[Issam Abed]

yeah, its going into a 2002 awp car

Then use that block with the AEG crankshaft

[1999.5GTIVR6]

Then use that block with the AEG crankshaft

my 1.8 block has a mount sheererd off the back, aswell i would rather not bore out the 1.8 to much (im also DDing it)

[Issam Abed]

my 1.8 block has a mount sheererd off the back, aswell i would rather not bore out the 1.8 to much (im also DDing it)

There is no difference between a 1.8T and 2.0 block...
one has an M14 tap @ the rear and is 81mm bore and the other has no M14 tap and is 82.5mm bore.
You can safely take either block to 83mm's.
That being said , I have a whole bunch of 82.5mm bore blocks that are brand new. Send over a PM for further details.

[harlequin80]

Do you sell a parts kit for this (minus management)? I already have an AEB head and can easily get an obd1 bottom end.

[Issam Abed]

Do you sell a parts kit for this (minus management)? I already have an AEB head and can easily get an obd1 bottom end.

since the creation of this thread I have sort of "modified" the advice I give people. Are you running digifant 1 or going straight to standalone?

[harlequin80]

The motor is goin into my harlequin so I'm guessing standalone?

[Issam Abed]

The motor is goin into my harlequin so I'm guessing standalone?

Then stay away from the ABA blocks. No real benefit to having them with 06A motors becoming so readily available.

[Prof315]

Then stay away from the ABA blocks. No real benefit to having them with 06A motors becoming so readily available.

Gotta disagree with you there. While it is more work to build a 20/20 with an ABA the long rod/ tall deck bottom end has it's advantages. The biggest advantage is torque. Tons and tons of torque.

[harlequin80]

I have a complete AEB motor. Someone said that I could run the motronic system on the 20v hybrid. What are the benefits/downsides to that? I know it is possible to wire the AEB motor into the factory mk3 system so I'm guessing there isn't much difference if it's NA vs FI

[Prof315]

I have a complete AEB motor. Someone said that I could run the motronic system on the 20v hybrid. What are the benefits/downsides to that? I know it is possible to wire the AEB motor into the factory mk3 system so I'm guessing there isn't much difference if it's NA vs FI

Just about anything can be done with enough time, patience, and cash. The question is, is it worth it? In my opinion NO. Standalone is very much the way to go. It can be done quite inexpensively and if you decide to make change to the motor once it's in (big turbo, cams, injectors, etc....) you don't have to get the ECU reflashed.

[Issam Abed]

Gotta disagree with you there. While it is more work to build a 20/20 with an ABA the long rod/ tall deck bottom end has it's advantages. The biggest advantage is torque. Tons and tons of torque.

...and the amount of work needed to do an ABA block he might as well do an ALH block and be done with it.
Unless you are running digifant-I or another block mounted distributor system , there is no need to use any of the old 827 blocks.
06A is the future , has been for sometime now.

[harlequin80]

So what is the ideal setup to use to throw it in a mk3 chassis? I have an 058 block that I was going to use when I wanted a BT 1.8T.

Also where can I find ITB's ?

[Issam Abed]

So what is the ideal setup to use to throw it in a mk3 chassis? I have an 058 block that I was going to use when I wanted a BT 1.8T.

Also where can I find ITB's ?

MKIII + 058 = correct combination. No modifications needed to the AEB motor to make it fit in the MKIII chassis.
There was a guy on here selling a set of ITB's recently. Search and it should be the first hit.

[harlequin80]

I know you can use the AEB block as it uses the same mounts and stuff as the ABA block. So basically what you are saying is to just build the motor I have to be N/A instead of turbo.

I just sold off the rods I had for it

I think Im going with the obd1 aba block anyways. Id still have to find a crank for the AEB motor and I can get a complete obd1 for less than a crank

[Issam Abed]

I know you can use the AEB block as it uses the same mounts and stuff as the ABA block. So basically what you are saying is to just build the motor I have to be N/A instead of turbo.

I just sold off the rods I had for it

I think Im going with the obd1 aba block anyways. Id still have to find a crank for the AEB motor and I can get a complete obd1 for less than a crank

Why would it matter if you sold the rods? N/A motors do not need forged rods , just ARP hardware on them. Get an OBD-I ABA crankshaft and throw it in the AEB block.

2.0 20V AEB

[harlequin80]

Because now I need rods again.
What rods/pistons would I use with an ABA crankshaft? Are they direct fit into the AEB block no mods needed?

[Issam Abed]

Because now I need rods again.
What rods/pistons would I use with an ABA crankshaft? Are they direct fit into the AEB block no mods needed?

You will need to grind the inside of the crankcase of the block to clearance the full swing of the connecting rod (actually the connecting rod bolts) but yes it can be a direct fit into an AEB block.

ABA Crankshaft + 144/20mm connecting rods + Mahle 92.8mm stroke pistons + AEB block = 2008cc AEB motor.

I would only attempt this if you absolutely want to stay with the 827 motors.

[wolfens_golf]

FIRST OFF....BUMP TO A GREAT THREAD. second id just like to say thanks for all the great advice. unfortunatly im noobish to the engine game so i do have some questions. yes i have read the majority of this thread but it can get alittle confusing.......on with the questions and my plans with the engine set up

91 corrado g60 planning to 20valve head swap...keeping dizzy & gladder

g60 block (PG)
AEB cly head
PG crank shaft(FORGED=BETTER)
AEB cyl head studs
AEB pistons & connecting rods
ABA OBD1 head gasket
AEB 20V camshat gear
PL intermediate shaft
AEB 20v gear(intermediate shaft)
16v wires
16v crankshaft pully
16v timing belt tensioner

honda preude timing belt 2.2 vtec 92-98

is this list correct? would i need a 16v dizzy?




also if i used a audi tt manifold what throttle cable do i need?
raising the compression....can i plane the head..if so how much?
i would require a chip for the digi 1?
the gladder is getting rebuilt....would one run a stock pully to "break in" then move to the 68 mm?