Username or Email Address
Do you already have an account?
Forgot your password?
  • Log in or Sign up

    VWVortex


    Page 1 of 7 12345 ... LastLast
    Results 1 to 35 of 235

    Thread: MK4/MKIV 2.0L 8v AEG/AZG -> 16v head swap

    1. Member elRey's Avatar
      Join Date
      May 15th, 2001
      Posts
      7,829
      Vehicles
      16vt 2.0L MK4 Jetta Wagon | B6 A4 Avant
      08-27-2008 05:13 PM #1
      MK4/MKIV 2.0L AEG/AZG + 16v head swap

      This is a budget build... $35 for 16v head, $50 for pistons/rods, etc

      work in progress. I'm lacking some aluminum welding of a TB relocation bend.

      t-belt -> 2004 LEXUS GS300 L6 3.0 Liter FI
      head bolts -> 91290A560 -> http://www.mcmaster.com (Issam Abed now offers ARP studs for this application.)

      I swapped 9A pistons and rods into a AZG/BEV block. The pistions had to be machined a bit to clear the oil squiters.

      AZG - modified 9A - stock 9A


      1.8T hybrid steel bottom oil pan... you never know when you might need an oil return line

      AZG/BEV bottom end assembled with 16v 9A rods and pistons. I reused the mk4 rod bearings and piston rings.:

      now some attention to the center of the swap, the 16v head:

      new stem seals, fine sanded all bearing and lifter surfaces and cleaned all gasket surfaces.

      Clean carbon off valves:



      head's assembled and time for mockups:

      need to relocate TB:


      MK4 coolant flange -> 16v head adapter:


      I'll be fitting a 20v CPS hall senosr wheel onto the 16v dizzy and use the dizzy as the CPS:


      Using an earlier AEG downpipe to mate with 16v exhaust mani. Having O2 bung welded on:

      Thanks,
      Rey



      Modified by elRey at 11:39 AM 7-21-2009


    2. Member 71DubBugBug's Avatar
      Join Date
      Dec 3rd, 2006
      Location
      Chicago
      Posts
      10,331
      Vehicles
      91 Audi D11 V8, 71 Super, 07 E320 Bluetec, 05.5 Jetta 2.5
      08-31-2008 02:28 AM #2
      thats a unique idea
      good luck!

    3. Member elRey's Avatar
      Join Date
      May 15th, 2001
      Posts
      7,829
      Vehicles
      16vt 2.0L MK4 Jetta Wagon | B6 A4 Avant
      09-07-2008 03:37 AM #3


      8v out.


    4. Member elRey's Avatar
      Join Date
      May 15th, 2001
      Posts
      7,829
      Vehicles
      16vt 2.0L MK4 Jetta Wagon | B6 A4 Avant
      09-08-2008 02:54 AM #4
      tranny separated and old 8v up on stand:

      front end swung open leaving A/C lines connected, waiting for 16v:





      older brother watching, remembering it's awkward swap (mk4 2.0L AZG + turbo from 1.8t):

      a little fancy hoist driving and 16v is docked:

      exhaust connected, coolant hoses, wiring, accesories on:


      Modified by elRey at 1:55 AM 9-8-2008


      Modified by elRey at 2:06 AM 9-8-2008


    5. 09-08-2008 03:03 AM #5
      COOL!

    6. 09-08-2008 06:50 AM #6
      man rey, i thought i had the hybrid edge...u have a double-edged sword! i have transmission ideas for adjusting shift points u make me wanna keep mine
      '11 Routan SE (black), '01 Jetta GLX VR6 5spd (silver)
      FE ///Motorsports VCDS Hex-Can, if you need help.

    7. Member fastgermancar's Avatar
      Join Date
      May 3rd, 2005
      Location
      818, CA
      Posts
      3,555
      Vehicles
      01 MR-S & 96 Jeep ZJ
      09-08-2008 08:37 AM #7
      niice
      SOLD: 2001 Molded and Shaved Jetta 2.0 Supercharged, I miss it
      SOLD: 92 8V Jetta Low'nSlow w/ Dual Rounds
      CURRENT: 2001 Toyota MR2 Spyder and a 1996 Jeep Grand Cherokee Limited 5.2
      Come check out my band Dante next time we play near you! Or at least click the

    8. 09-08-2008 01:08 PM #8
      Watching!

    9. Member microzimmer's Avatar
      Join Date
      Dec 19th, 2005
      Location
      GA
      Posts
      2,064
      Vehicles
      95 855
      09-09-2008 09:44 PM #9
      in for the watch

    10. Member elRey's Avatar
      Join Date
      May 15th, 2001
      Posts
      7,829
      Vehicles
      16vt 2.0L MK4 Jetta Wagon | B6 A4 Avant
      09-10-2008 01:41 AM #10
      started it up tonight.

      first I pulled the fuel pump and injector fuse and I disconnected the coil pack and ran the starter for a minute to get the fresh oil circulating.

      I then replace the fuel pump fuse and cycled the ign a few times to look for any fuel leaks.

      Then I replaced the injector fuse and reconnected the coil pack.

      It fired right up. Though, with a major exhaust leak that I knew about and #4 cyl misfiring. I only let it idle for a minute.

      The exhaust leak is from a threaded hole in the mani I have yet to find a bolt to plug it. The misfire... I don't know yet. I have to address the pancaking silicone bend after the TB before I start it up again.

      .
      .
      .

      still have to:
      1) torque the drive shaft flanges
      2) find/fab a dizzy cover
      3) figure out intake
      4) lengthen MAF wires
      5) address silicone after TB
      6) find bolt to plug hole in exhaust mani
      7) address #4 cyl misfire (God willing, this will go away)



      Modified by elRey at 12:44 AM 9-10-2008


    11. 09-10-2008 06:58 AM #11
      awesome job rey. just awesome. we should meet up for a auto 16v ride
      '11 Routan SE (black), '01 Jetta GLX VR6 5spd (silver)
      FE ///Motorsports VCDS Hex-Can, if you need help.

    12. Member elRey's Avatar
      Join Date
      May 15th, 2001
      Posts
      7,829
      Vehicles
      16vt 2.0L MK4 Jetta Wagon | B6 A4 Avant
      09-11-2008 02:57 AM #12
      Quote, originally posted by rychas1 »
      awesome job rey. just awesome. we should meet up for a auto 16v ride

      Thanks man. Let me make sure it'll stay together, but after that, sure! But I would never expect it to keep up with yours.


    13. 09-11-2008 10:13 AM #13
      From the noob corner...inspired , you have laid the blue prints for my winter project. I am painting my chariot now and the engine is next. What's the biggest hurdle you have had to overcome so far in this project?

      I'll be watching..


    14. 09-12-2008 01:25 PM #14
      Subscibed for a super sweet build. This should have been the base engine in the MkIV!

    15. Member elRey's Avatar
      Join Date
      May 15th, 2001
      Posts
      7,829
      Vehicles
      16vt 2.0L MK4 Jetta Wagon | B6 A4 Avant
      09-17-2008 12:19 AM #15
      It been running for 600 miles now:


    16. Member microzimmer's Avatar
      Join Date
      Dec 19th, 2005
      Location
      GA
      Posts
      2,064
      Vehicles
      95 855
      09-17-2008 12:24 AM #16
      Quote, originally posted by elRey »



      very clean

    17. 09-17-2008 01:59 AM #17
      cool swap

    18. Moderator 71sbeetle's Avatar
      Join Date
      Apr 12th, 2002
      Location
      West Palm Beach, Florida
      Posts
      30,633
      Vehicles
      1971 Super Beetle, 2013 Passat TDI SEL Premium, 2014 Golf TDI Manual
      09-17-2008 12:22 PM #18
      so, what are the difference in feel from the 8V to the 16V ? noticeable ? gas mileage ?

    19. Member IFlyGTI's Avatar
      Join Date
      Feb 26th, 2001
      Location
      Sacramento area, CA
      Posts
      4,046
      Vehicles
      2003 20th Anniversary GTI, 1966 Variant, 1976 Bunny, 1996 GTI VR6, 1991 Variant
      09-20-2008 04:54 PM #19
      Quote, originally posted by elRey »


      You are my new hero. I was curious about what other people are watching and stumbled across this thread. I honestly had to dig through my ETKA to make sure they didn't actually offer this combo somewhere (besides here). Looks pretty factory to me & for that, I grant you and a .
      Mike S. SacWater
      '03 20th Anniversary - '96 GTI VR6
      '91 B3 Variant - '76 Mk1 - '66 T3 Variant
      *Duc*Duc*Hawk(GT)*
      The Ranch Run - Wuste "Cogito, ergo zoom!" RIP David E.

    20. Member CodeMan's Avatar
      Join Date
      May 12th, 2006
      Location
      Denverish
      Posts
      7,737
      Vehicles
      Scirocco 16v, E34 540i
      09-20-2008 11:06 PM #20
      Quote, originally posted by microzimmer »

      very clean

      Agreed. It looks so right.

      The blues ain't nothin' but a good man feelin' bad.

      Tschüß Gilda
      Hallo Birgit

    21. Member gogogadget's Avatar
      Join Date
      Apr 13th, 2007
      Location
      In an Igloo
      Posts
      2,232
      Vehicles
      a TT
      09-21-2008 05:27 PM #21
      bump for hp gains, differences before and after, woudl love to do this to my mkiv over winter

    22. 09-28-2008 10:19 PM #22
      Quote, originally posted by 71sbeetle »
      so, what are the difference in feel from the 8V to the 16V ? noticeable ? gas mileage ?

      Yes, to the OP please tell us about gains, feel, how it drives, etc.


      Modified by randallhb at 8:23 PM 9-28-2008


    23. Member sickmind's Avatar
      Join Date
      Dec 9th, 2003
      Posts
      1,503
      Vehicles
      90` 16V corrado , 95` Jetta , 93` 240sx , 70` Triumph T100
      09-30-2008 07:30 PM #23
      I was just wondering what plug wires you used and how you went about setting up the dizzy as the CPS ,

    24. Member 16VTrash's Avatar
      Join Date
      Feb 13th, 2008
      Location
      peehndub
      Posts
      862
      10-02-2008 09:30 PM #24
      gotta see
      16V TURBO KIT FS + accessories
      PM ME

      so bright as headlights loud speakers and my car being lowerd is a bad thing your stupid dude gtfo of here.

    25. Member SMG8vT's Avatar
      Join Date
      Oct 8th, 2004
      Location
      Nova Scotia
      Posts
      3,276
      Vehicles
      '00 Beetle R32, '66 Beetle Project
      10-03-2008 08:55 PM #25
      Quote, originally posted by sickmind »
      I was just wondering what plug wires you used and how you went about setting up the dizzy as the CPS ,

      Wondering the same thing myself. SICK build man, congrats.


    26. Banned
      Join Date
      Aug 25th, 2008
      Posts
      1,494
      10-08-2008 10:47 PM #26
      x2 also did you have to change the intermediate shaft gears and what not like the aba guys? or is this entire motor mk4 minus head pistons rods and timming belt?

    27. Member elRey's Avatar
      Join Date
      May 15th, 2001
      Posts
      7,829
      Vehicles
      16vt 2.0L MK4 Jetta Wagon | B6 A4 Avant
      10-08-2008 11:01 PM #27
      Quote, originally posted by 2LTurbo »
      or is this entire motor mk4 minus head pistons rods and timming belt?


      excatly


    28. Banned
      Join Date
      Aug 25th, 2008
      Posts
      1,494
      10-08-2008 11:09 PM #28
      wtf ?! how! seriously the aba guys say it CANT be done without switching those other things... also how did you tackle the CPS man?

    29. Member elRey's Avatar
      Join Date
      May 15th, 2001
      Posts
      7,829
      Vehicles
      16vt 2.0L MK4 Jetta Wagon | B6 A4 Avant
      10-08-2008 11:15 PM #29
      CPS is in the thread....

      stock 16v distributor + 20v trigger wheel
      I cut/grind the 16v trigger wheel down just enough to slide the 20v wheel over it, then tack welded it.

      Quote, originally posted by elRey »
      I'll be fitting a 20v CPS hall senosr wheel onto the 16v dizzy and use the dizzy as the CPS:





    30. Banned
      Join Date
      Aug 25th, 2008
      Posts
      1,494
      10-08-2008 11:20 PM #30
      elray i love you, why wont you answer my pm's haha for a turbo setup would you recommend the 9a pistons or can i use my brand new aeg pistons i bought and just notch them?

    31. Banned
      Join Date
      Aug 25th, 2008
      Posts
      1,494
      10-09-2008 12:31 AM #31
      oh also what did you use for head bolts?

    32. Member elRey's Avatar
      Join Date
      May 15th, 2001
      Posts
      7,829
      Vehicles
      16vt 2.0L MK4 Jetta Wagon | B6 A4 Avant
      10-09-2008 12:48 AM #32
      Quote, originally posted by 2LTurbo »
      oh also what did you use for head bolts?

      91290A560 -> http://www.mcmaster.com


    33. Banned
      Join Date
      Aug 25th, 2008
      Posts
      1,494
      10-09-2008 01:11 AM #33
      what about using arp head studs. would i use the 16v ones or 8v ones?

    34. Banned
      Join Date
      Aug 25th, 2008
      Posts
      1,494
      10-09-2008 01:22 AM #34
      sorry i know i must sound like a lil girl. im just excited, but where did you get the MK4 coolant flange -> 16v head adapter:

    35. Banned
      Join Date
      Aug 25th, 2008
      Posts
      1,494
      10-09-2008 02:36 AM #35
      and did you use the 16v cam gear?

    Page 1 of 7 12345 ... LastLast

    Posting Permissions

    • You may not post new threads
    • You may not post replies
    • You may not post attachments
    • You may not edit your posts
    •