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

[duke_seb]

this is what i mean

[Shifty]

Quote, originally posted by duke_seb »

this is what i mean

It took me a second to get on board with that idea, but it does seem like a cheaper alternative for us non-CAD-using folk! I was getting ready to try fab'ing something out of 1/2" aluminum plate by hand tomorrow... I think I'm going to try that instead.

[duke_seb]

after thinking abot this some more.... i have to take a look at the 16v flange..... its at the machine shop..... I am going to see if i can cut both of the pipes on the flange and then weld both to the plate then you have 2 ports coming into the head

[duke_seb]

alright i started on fabricating my version of the mount today here are some pictures

i intend on welding that side hole shut

[Shifty]

Cool deal man! Why didn't you cut it closer to the head and eliminate that second tube altogether?

[duke_seb]

i thought about that but then i wouldnt be able to get the bolts into the holes to put into the head

Quote, originally posted by Shifty »

Cool deal man! Why didn't you cut it closer to the head and eliminate that second tube altogether?

[Shifty]

Roger that, thanks. Keep us posted as to how it works!

[duke_seb]

i will.... i think im going to make another DIY for this.... with everything from replacing rod bearings to whatever use i have to do..... with lots of pictures

[duke_seb]

alright i got the piece welded together today here are some pics

[Shifty]

Someone mentioned to me that I have a Rocco exhaust mani and that it appears you're using an A2 mani. I assume the Rocco one will not work?

[duke_seb]

ok here is the question i have..... i ordered a 16V Fuel Rail from bahn brenner... but i dont think i have the right one.... can someone tell me if both of these will work?

and

do i have to have this part in order to make it work?

Modified by duke_seb at 10:16 AM 5-27-2009


Modified by duke_seb at 10:16 AM 5-27-2009

[doodpod]

Quote, originally posted by duke_seb »

do i have to have this part in order to make it work?

Yes.

[Shifty]

BBM told me I could use either one of those adapters. they said you only need the canister style if you want to retain the stock MkIV reg. Might give them a call for more details, but i'm sure you can make it work.

[duke_seb]

OK im looking through the bentley and I have a BEV engine correct me if im wrong here but with the BEV the FPR is part of the fuel filter back by the tank..... I just want to be sure before i do this but i should be able to run the fuel line right to the fuel rail without a FPR Adaptor correct?

[duke_seb]

here is an example of what my engine looks like

[Shifty]

Quote, originally posted by duke_seb »

here is an example of what my engine looks like

Huh. Makes sense to me. My car has the FPR there at the end of the rail so I went with the "canister" adapter.

[duke_seb]

if thats the case.... it looks like the BEV and BBW engine is a litle easier

[duke_seb]

Quote, originally posted by Shifty »

Huh. Makes sense to me. My car has the FPR there at the end of the rail so I went with the "canister" adapter.

my MKIII had it at the end too.... when i popped the hood to do some research i thought i was retarted.... I was like.... where they hell is that stupid thing..... i was following the fuel line and everything.... went back to the bentley and i noticed it was missing from the BBW engine diagram..... and then i thought OMG i have the dredded BBW..... but from what i can tell BBW only came on Jettas..... but then i verfied it in the car and in the manual that BEV and BBW both have the FPR back in the tank

[elRey]

Quote, originally posted by duke_seb »

if thats the case.... it looks like the BEV and BBW engine is a litle easier

until you want to upgrade your fueling

[duke_seb]

im not planning anything special..... just want to have a stock 16V

[elRey]

Quote, originally posted by duke_seb »

im not planning anything special..... just want to have a stock 16V

lol. so did I

in fact, I looked into swapping in the BWW/BEW fuel system to avoid needing a FPR for a cleaner engine bay.


Modified by elRey at 9:56 PM 5-27-2009

[duke_seb]

haha.... no really im serious.... im already into this build for like 1500 bucks..... its not the big stuff that gets you its the little stuff... like orings and oil filters and oil and gaskets....etc etc.... ill be quite happy with a stock 16V.... once i get that one there im going to get C2 Software for more power and to get rid of the CEL from the SAI

my MKIII with a cam and chip couldnt even touch a stock 16V ..... and i drove that for 6 years.... i might consider something else but then i have to replace the FPR the Clutch ..... etc etc etc...eeeek

[duke_seb]

elrey what did you do about this vacuum port on the lower intake... i dont even see it on yours...... i looked through every opening on the lower intake and i cant even see where it even goes... but anyway I was thinking of running the Vacuum line that goes into the side of the MKIV 2L Upper intake and running it down to the lower one? what you think?

Modified by duke_seb at 8:54 PM 5-30-2009

[elRey]

Quote, originally posted by duke_seb »

elrey what did you do about this vacuum port on the lower intake... i dont even see it on yours...... i looked through every opening on the lower intake and i cant even see where it even goes... but anyway I was thinking of running the Vacuum line that goes into the side of the MKIV 2L Upper intake and running it down to the lower one? what you think?

It goes to the injectors. If you pull the old injector seats out and look at threads you can see a hole. I left the port open. The digi injector seats cover the inside hole. If you want you can just put a rubber vac plug over it. It will not see vacuum.

[elRey]

I took quick look back and I don't think I've posted my current setup (life beyond the head swap):

MK4 Jetta Wagon 16vT build

Modified by elRey at 7:24 PM 5-31-2009

[duke_seb]

Alright I have quick question for you.... i noticed that you have a block off from the front coolant flange on the 16V..... can you explain to me how this works..... i mean im not totally sure what happens..... i assumed that with the 16V coolant came in through the side and went out threw the front?...... im probably wrong..... but is there openings in the bottom of the head to allow coolant to drain down and go into the block and out the MKIV front coolant flange?.....

[elRey]

16v head has all the same coolant ports as 8v head at the block mating surface. Coolant gets pushed up from the block to the head past the head gasket and then out the side thru the coolant flange.

[jettaiv4turbochrg]

[duke_seb]

ok elrey.... i missed the stupid cutout when i was trming the skirts..... so i dont have to take the engine apart to figure out where is supposed to be can you tell me which dot represents the spot where the cutout for the oil squiters is?

[elRey]

I don't remember off hand, but the 1.8t guys should know. They're in the same spot on the 1.8t.

[duke_seb]

are they in the same spot as the original 2L 16V? cuz i have another one i have access to to look

[duke_seb]

figured it out.... took my MKIV 2L piston to the dealer and asked them which way faced the belts.....

the notch is on the front of the engine

[duke_seb]

Hey elrey can u tell me what the difference between 16v and mkiv rods are I have them side by side and I can't see a reason why u can't use the rods out of a mkiv

[elRey]

Quote, originally posted by duke_seb »

Hey elrey can u tell me what the difference between 16v and mkiv rods are I have them side by side and I can't see a reason why u can't use the rods out of a mkiv

I'm guessing you have AEG mk4 rods in front of you. While AEG rods do look similar to 9a rods, AZG/BEW rods are totally different.

20mm pin vs 19mm pin. straight cut vs tapered small ends. and 9a are beefier than AZG/BEW.

Even the AEG rods are slightly different and are not an exact fit into 9a pistons. Or at least the pins. IIRC, the 9a pins are longer than AEG pins.

[duke_seb]

I actually have 1.8t rods and they look the same as the 9a ones.... Any reason I shouldn't use them I was told they are fine that they were just lighter