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

[DubChub]

Quote, originally posted by elRey »

The exhaust leak is from a threaded hole in the mani I have yet to find a bolt to plug it.

this was a while ago, so you probably already found one. And I'm not 100% on 16v manifolds... And this may also sound a bit strange.. But....

Do you have any spare wheel bolts? (I've done this on ABA/Early 8v Manifolds.)

[elRey]

Yeah, I had it covered moments after I post that way back. I believe it was a M10x1 (fine) bolt. However, that manifold's been long gone

[mannythechamp]

rey can u help me ??? plzzz

im reallly interested into doing this swap since it isnt very inexpensive to do considering getting a deal with the 16v head now i have an AEG 8v 2.0 on a 2000 golf i want to do this i just want to know if its something attainable in an easy way or should i just stick to a new autotech cam and springs..
help me out i read that if i dnt turbo this setup i actually loose CR is that true what do you recommend so many people telling me different things and i dont know what to do anymore

well anyways i appreciate the help thanks man
manny

[elRey]

major obstacles:

- custom coolant flange adapter
- custom throttle body adapter
- cam position sensor (dizzy)

[mannythechamp]

do i need new pistons to not loose CR because i cnt afford boost right
now thanks

[elRey]

it's good to have this back.

[raymondlee]

dreading the distro thing

[m_eventos]

just a quick question, what headgasket did you use, how did you cover the 3 oil return holes in the block since they do not match the 16v head?

[elRey]

used a mk4 2.0L head gasket. The head gasket is closed over those oil return holes. Tho the head doesn't quite cover the holes 100%, the head gasket does. So, with lower crankcase pressure there should be an issue. I haven't had any.

[MK1_F00L]

Been following this thread a little and am doing a similar project just with a 1.8t bottom end I see how you installed the CPS did you give any thought to using the cam gear from the Mk4 motor as the CPS is attached to it on the 2.0L as well having both both cam gears side by side they do look the same. Would there be any reason not to try this way and get a block off plate for the distributor? I can take photos if that will help?


Either way awesome project makes me feel better that I wasn't crazy on how I was going about thing for my motor

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:

[raymondlee]

was thinking the same thing. i think he said he didnt want to make the provision to the head to bolt the cps sensor to the 16v head or either it was clearance issues.. I am about to get back on this.

[elRey]

You can't just drill/tap mounting holes for the sensor into the head. You would need to machine a spot for the sensor to clear the gear. And doing so, you would need to make sure you don't interfere with coolant passages. Also, the 2.0L gear is keyed differently than the 1.8T/16v gear to fix on the camshaft. To get around that you could spot weld the trigger wheel from a 2.0L gear onto the back of a 1.8T/16v gear, but then it makes it just as much work as what I did.

I explored that route and even went as far as separating a trigger wheel off a 2.0L gear and test fitted a 2.0L sensor under a gear.

[Mk41.8t]

very nice

[VdubPipoz]

Back from the dead!

just a quick question im going to the junker on saturday in exactly what year and volks can i find a dohc 16v head?

[o2bad455]

I think the 16V heads for this thread (1.8L PL and 2.0L 9A engines in North America) can be sourced from:
90-93 Passat 16V
87-92 GTI 16V
87-92 GLI 16V
86-89 Scirocco 16V

If you want the 2.0L 16V pistons too, the donor would have to be a 90-93 Passat, GTI or GLI (9A engine). Note that many were 8V instead of 16V, so don't buy sight unseen.

That said, I wonder if a later FSI 16V head could be used, perhaps with MegaSquirt. Any thoughts?

[blankblank]

@ elRey
I tried searching this thread but couldn't find what exhaust manifold you used to bolt up the stock mk4 2.0l downpipe...what are the options?

Btw trying to source all the parts for pretty identical build and it is hard...i am starting to give up slightly

[vwpat]

@ elRey
I tried searching this thread but couldn't find what exhaust manifold you used to bolt up the stock mk4 2.0l downpipe...what are the options?

mk2/passat 16v manifold.

[Albertkvw]

good stuff, this could be an option one day

[jjensen]

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

,



hey rey is the location of the tdc window edge on the 1.8t trigger wheel the 100 percent correct in the picture?

[elRey]

It's been a while, but I think I made a correction after more research.

use these as reference:
http://www.wetdub.com/phpBB3/viewtopic.php?t=9006

http://www.audizine.com/forum/showth...nsor-alignment

[jjensen]

so its the next window clock wise. which edge should i mark as tdc?

[elRey]

That's the way I see it. I'd mark the leading edge, but anywhere between the leading and falling edge is fine 1) because you can rotate the dizzy 2) it doesn't have to be dead on. The ECU uses the crank position sensor for precise angle and big/small windows on trigger wheel for which stroke it's on.

[jjensen]

thanks i owe you one

[RedVirus80]

I have a 01 2.0 aeg 8v...Could I use a 16v head off a mk4 1.8 and if so would I have to do anything to the ecu? also why the tb from the lexus?...thicker? I like to do a head swap or beef up what I got now but don't know where to find the complete kits.

[Sunnyboy1979]

If you would give me the scamatics of your build, from start to finish. I too woud like to convert a 16v head on my block.

Thanks

[vwpat]

If you would give me the scamatics of your build, from start to finish. I too woud like to convert a 16v head on my block.

Thanks

the first page has pretty much all you need. Ther eare some custom parts needed but I do not know if Rey or anyone else has schematics for them.

[nanderdubfan]

I have a 01 2.0 aeg 8v...Could I use a 16v head off a mk4 1.8.

x2 does anyone know the answer to that?

[vwpat]

x2 does anyone know the answer to that?

No Mk4s, in NA at least, came with a 16V head. If you mean the 20V head then yes but that is another thread.

[rjcmets5]

was wondering what specific year/make head and intake manifold you used and also did you use the throttle body from the mk4 2.0

thanks

[elRey]

was wondering what specific year/make head and intake manifold you used and also did you use the throttle body from the mk4 2.0

thanks

head: 1992 passat
intake: scirocco drive-side TB intake mani
TB: 2002 2.0L AZG

[scirocconaut]

I just happen to have a Aeg block and a 16v head in my carport,
I knocked out the guide pins out of curiosity

Glad to see this thread

[rjcmets5]

Was wondering if someone knew these answers. The 1.8t elray is getting the cam gear from and hall sensor wheel is from what year car? Also will that fix my problem getting the 1.8t cam gear so the crank gear lines up evenly with the cam gear for the timing?

[rjcmets5]

x2 does anyone know the answer to that?

It's a 20v head from an mk4 not 16v

[elRey]

cam gear is from a later, interal waterpump, 1.8T.
The early 1.8T (AEB) had external waterpumps. Those use the same cam gear as the 16v and will NOT work. Cam gear must be from a later 1.8T 20v with an internal waterpump.

AEB (external waterpump) = PASSAT/A4 1998-2000


everything else = internal waterpump

Same for the distributor/CPS 4-window trigger wheel.

[rjcmets5]

thank you