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

    1. Member elRey's Avatar
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      08-27-2008 04:13 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
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      08-31-2008 01:28 AM #2
      thats a unique idea
      good luck!

    3. Member elRey's Avatar
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      09-07-2008 02:37 AM #3






      8v out.

    4. Member elRey's Avatar
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      09-08-2008 01:54 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 02:03 AM #5
      COOL!

    6. 09-08-2008 05:50 AM #6
      man rey, i thought i had the hybrid edge...u have a double-edged sword! [IMG]http://**********************/smile/emthup.gif[/IMG] i have transmission ideas for adjusting shift points u make me wanna keep mine
      '11 Routan SE (black), '01 Jetta GLX VR6 5spd (silver)
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    7. Member fastgermancar's Avatar
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      09-08-2008 07:37 AM #7
      niice
      SOLD: 2001 Molded and Shaved Jetta 2.0 Supercharged, I miss it
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    8. 09-08-2008 12:08 PM #8
      Watching!

    9. Member microzimmer's Avatar
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      09-09-2008 08:44 PM #9
      in for the watch

    10. Member elRey's Avatar
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      09-10-2008 12:41 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 05:58 AM #11
      awesome job rey. just awesome. we should meet up for a auto 16v ride [IMG]http://**********************/smile/emthup.gif[/IMG]
      '11 Routan SE (black), '01 Jetta GLX VR6 5spd (silver)
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    12. Member elRey's Avatar
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      09-11-2008 01:57 AM #12
      Quote, originally posted by rychas1 »
      awesome job rey. just awesome. we should meet up for a auto 16v ride [IMG]http://**********************/smile/emthup.gif[/IMG]

      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 09:13 AM #13
      From the noob corner...inspired [IMG]http://**********************/smile/emthup.gif[/IMG] , 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 12:25 PM #14
      Subscibed for a super sweet build. This should have been the base engine in the MkIV!

    15. Member elRey's Avatar
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      09-16-2008 11:19 PM #15
      It been running for 600 miles now:



    16. Member microzimmer's Avatar
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      09-16-2008 11:24 PM #16
      Quote, originally posted by elRey »

      very clean

    17. 09-17-2008 12:59 AM #17
      cool swap [IMG]http://**********************/smile/emthup.gif[/IMG]

    18. Moderator 71sbeetle's Avatar
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      09-17-2008 11:22 AM #18
      so, what are the difference in feel from the 8V to the 16V ? noticeable ? gas mileage ?

    19. Member IFlyGTI's Avatar
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      09-20-2008 03:54 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 [IMG]http://**********************/smile/emthup.gif[/IMG] [IMG]http://**********************/smile/emthup.gif[/IMG] and a .
      Mike S. SacWater
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    20. Member CodeMan's Avatar
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      09-20-2008 10:06 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
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      09-21-2008 04:27 PM #21
      bump for hp gains, differences before and after, woudl love to do this to my mkiv over winter

    22. 09-28-2008 09:19 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
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      09-30-2008 06:30 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
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      10-02-2008 08:30 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
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      10-03-2008 07:55 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. [IMG]http://**********************/smile/emthup.gif[/IMG] [IMG]http://**********************/smile/emthup.gif[/IMG]

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