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

[The Kilted Yaksman]

Right about 140hp and 150ft/lb of torks. Nice! Definitely what should have been the stock base engine.

[the_q_jet]

nice build are you still using me7 ecu??... el did you ever dyno that k03 2.0 setup?


Modified by the_q_jet at 5:45 AM 3-5-2009

[elRey]

Quote, originally posted by the_q_jet »

nice build are you still using me7 ecu??... el did you ever dyno that k03 2.0 setup?

Yes, stock ME7.5 management.

Wagon just passed emissions with flying colors.


Modified by elRey at 10:10 PM 3-22-2009

[rtbtitans50]

nice swap

[doodpod]

Just curious, how did you deal with the SAI? I don't see it in any of your pics.

[nick526]

Quote, originally posted by V8Star »

if this is Smog-able in CA.

Nope. Won't pass visual unless the tech is very careless.


Modified by nick526 at 1:35 AM 4-14-2009

[elRey]

Quote, originally posted by doodpod »

Just curious, how did you deal with the SAI? I don't see it in any of your pics.

I never put the SAI back in. GA doesn't require visual inspection.

BUT, you could go the extra mile and use the SAI pump bracket and hoses from an 1.8T to relocate the pump down near the oil pan. Then do some custom piping to the back of the exhaust mani. The mani has a threaded port you could use. I just plug it with a bolt.

[doodpod]

Quote, originally posted by elRey »

I never put the SAI back in. GA doesn't require visual inspection. BUT, you could go the extra mile and use the SAI pump bracket and hoses from an 1.8T to relocate the pump down near the oil pan. Then do some custom piping to the back of the exhaust mani. The mani has a threaded port you could use. I just plug it with a bolt.

I'm sorry, I should have been more specific - I figured you'd just relocated it since I couldn't see it. If you eliminated it, and are running stock management, do you have a CEL? Or do you know a trick for not tripping the CEL (resistor or otherwise?)

[elRey]

No. I know there's a period of time after you clear codes and when the ECU runs the SAI diagnostic test on the SAI enough times to throw a DTC and CEL. I reset the codes and force all readiness codes except SAI. GA emissions allows for one readiness to be failed/incomplete. So, I got it tested with all but that one SAI readiness code set and before the incorrect flow DTC shows up.

CEL shows up eventually.

Why would a visual inspection fail if the SAI is present, just relocated. Do the inspectors know where the SAI pump is located for ever model and engine?


Modified by elRey at 6:30 PM 4-16-2009

[all-starr-me]

Quote, originally posted by elRey »

Why would a visual inspection fail if the SAI is present, just relocated. Do the inspectors know where the SAI pump is located for ever model and engine?

it wouldn't, it would fail for having the wrong cylinder head in place, plus a diiferent intake, omong other things. california sucks. on second thought you probably would fail just for moving the air pump, even if you kept it.

this is what VW should have done from the factory in the mk4's, but maybe a cleaner looking intake and some work on the head. The AEG and later 2.0's are the worst engines ever, I would rather have a G60 without the charger.

[16vturbo gti]

wtf? some one relised that a 16v is better then a 1.8t nice work

[MK1 Rabbit GTI]

they use a lot of 16v's in europe

[Shifty]

My God I love it man. I might just go this route on the wifes build.

[duke_seb]

do you have info on those machined parts that you made?......

[duke_seb]

anyone know of any reason why this swap wouldnt work on a BEV 2L

[Shifty]

I started ordering parts tonight and my wife and I began pulling out the 2.slow.

[Shifty]

Was the TB flange custom made as well?

[elRey]

Quote, originally posted by Shifty »

Was the TB flange custom made as well?

this: http://www.bahnbrenner.com/vw_..._to_3

plus the TB side of this: http://www.bahnbrenner.com/vw_...MkIII - call them, they will sell just the TB flange.

and a silicone coupler.

[Shifty]

Quote, originally posted by elRey »

this: http://www.bahnbrenner.com/vw_..._to_3 plus the TB side of this: http://www.bahnbrenner.com/vw_...MkIII - call them, they will sell just the TB flange. and a silicone coupler.

Thanks bro.

I called them and asked about one earlier today, they said it wasn't available.

Tonight I'm ordering my BBM parts and pulling the motor. Hopefully everything goes smoothly... just found out my machinist closed shop and moved to Utah three weeks ago so I need to find someone else I trust to do my machine work...

Edit: Just called BBM again, apparently the adapter isn't available after all. They're sold out and none are scheduled to be machined until next month at the soonest. x2


Modified by Shifty at 5:39 PM 5-18-2009

[elRey]

Quote, originally posted by Shifty »

Thanks bro. I called them and asked about one earlier today, they said it wasn't available. Tonight I'm ordering my BBM parts and pulling the motor. Hopefully everything goes smoothly... just found out my machinist closed shop and moved to Utah three weeks ago so I need to find someone else I trust to do my machine work... Edit: Just called BBM again, apparently the adapter isn't available after all. They're sold out and none are scheduled to be machined until next month at the soonest. x2 Modified by Shifty at 5:39 PM 5-18-2009

I can sell mine for what I paid. LMK.

[Shifty]

Quote, originally posted by elRey »

I can sell mine for what I paid. LMK.

PM sent.

[duke_seb]

Quote, originally posted by elRey »

I can sell mine for what I paid. LMK.

do u still have it?.... ill pay today

[doodpod]

What injectors did you use?

[elRey]

I used BWW or BEV injectors with a 4bar fpr only because they don't need a fresh-air hose running to them.

[Shifty]

Hey elrey, I sent another PM regarding that TB adapter. Thanks!

[elRey]

Replied

[doodpod]

Quote, originally posted by elRey »

I used BWW or BEV injectors with a 4bar fpr only because they don't need a fresh-air hose running to them.

Any chance it might make more power with a dual-spray cone injector? The smallest ones on USRT's website are 315cc units; dunno if that'd be too much for the stock management to compensate for. Maybe stock 1.8t units would work?

[duke_seb]

incase anyone is looking for specs on that coolant adaptor let me know.... im having one made and it costing me 300 bucks for the custom work.... ill sell the specs to ya for cheap so you can get your made for cheaper

[elRey]

Quote, originally posted by duke_seb »

incase anyone is looking for specs on that coolant adaptor let me know.... im having one made and it costing me 300 bucks for the custom work.... ill sell the specs to ya for cheap so you can get your made for cheaper

you mean this?

[duke_seb]

AWESEOM..... you rock!

you might same me some cash

[duke_seb]

do you have any non moving diagrams with measurements?

[duke_seb]

ok.... I just got them to design the piece for me..... but one thing I didnt think about until now is y not just get a piece made that the same as the plastic flange and then weld the 16V piece to it then obviously cut off and well the other opening shut

i dont know but it seems to me that would be a little cheaper?

[Yurko]

gruvenparts might help you out.

[elRey]

Quote, originally posted by duke_seb »

ok.... I just got them to design the piece for me..... but one thing I didnt think about until now is y not just get a piece made that the same as the plastic flange and then weld the 16V piece to it then obviously cut off and well the other opening shut i dont know but it seems to me that would be a little cheaper?

That's fine until for whatever reason you need to replace the head. Then you have to have all that custom work done again.

[duke_seb]

y would that be you can still unbolt the 16v flange and away you go