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

[elRey]

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

[71DubBugBug]

thats a unique idea
good luck!

[elRey]

8v out.

[elRey]

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

[djpj06]

COOL!

[rychas1]

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

[fastgermancar]

niice

[Veedubgti]

Watching!

[microzimmer]

in for the watch

[elRey]

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

[rychas1]

awesome job rey. just awesome. we should meet up for a auto 16v ride

[elRey]

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.

[gobaroonie20]

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..

[The Kilted Yaksman]

Subscibed for a super sweet build. This should have been the base engine in the MkIV!

[elRey]

It been running for 600 miles now:

[microzimmer]

Quote, originally posted by elRey »

very clean

[2doorV6]

cool swap

[71sbeetle]

so, what are the difference in feel from the 8V to the 16V ? noticeable ? gas mileage ?

[IFlyGTI]

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 .

[CodeMan]

Quote, originally posted by microzimmer »

very clean

Agreed. It looks so right.

[gogogadget]

bump for hp gains, differences before and after, woudl love to do this to my mkiv over winter

[randallhb]

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

[sickmind]

I was just wondering what plug wires you used and how you went about setting up the dizzy as the CPS ,

[16VTrash]

gotta see

[SMG8vT]

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.

[2LTurbo]

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?

[elRey]

Quote, originally posted by 2LTurbo »

or is this entire motor mk4 minus head pistons rods and timming belt?

excatly

[2LTurbo]

wtf ?! how! seriously the aba guys say it CANT be done without switching those other things... also how did you tackle the CPS man?

[elRey]

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:

[2LTurbo]

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?

[2LTurbo]

oh also what did you use for head bolts?

[elRey]

Quote, originally posted by 2LTurbo »

oh also what did you use for head bolts?

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

[2LTurbo]

what about using arp head studs. would i use the 16v ones or 8v ones?

[2LTurbo]

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:

[2LTurbo]

and did you use the 16v cam gear?