For people who want to do a 2.0 ABA 16vt or NA low compression this is a generic list for adapting this hybrid combo to mk1-mk2-mk3 chassis
16v ABA OBD1 notes can also be used with OBD2 just use OBD2 sensors and ecu harness.
This yields low compression NA (to be boosted later on) this combo yields a 8.5-1 compression ratio and is perfect to boost, the obd1 motronic engine wiring harness plugs directly into ce2 fuse blocks
To make this a 10.5-1 compression motor add ABF pistons from INA or BBM
Pistons from a 9a & rods from aba re-brushed = 9.2:1. However if you use a 95.5 mm TDi crank those pistons just about perfectly compensate for the extra 1.35 mm stroke of that crank.
I used mainly BBM and blackforest for part number references parts can be sourced from other suppliers or can be fabricated yourself.
Parts: (I listed the early ABA obd 2.0 because it came with oil squirt and forged crank)
complete 2.0 aba from 93-95 jetta gti (oil squirt and forged crank able to run obd1)
check for valve clearance might need relief cuts in pistons
oil pump, intermediate shaft + gear, dizzy adp, crank gear from a 9a block (BBM has a kit if you can not source these parts BBM part #226101222)
16v head from gli,gti,passat,scirocco
I have heard the 1.8 heads flowed better than the later 9a 16v heads anyone can confirm?
brake booster line from 16v
obd1 intake boot and maf and throttle body
use GTI/jetta intake if you want pass side throttle body use scirocco manifold if you want driver side throttle body (there are a variety of sizes from 40mm to 50mm intakes for DOHC 16v)
Alt and brackets from mk3 serp setup can be used with PS and AC
timing belt aba 16v (BBM part # 226101500)
fuel rail (BBM part #226100693) FPR (BBM part #226100357) lines and fittings not included
other fuel rail options http://forums.vwvortex.com/showthrea...ck-intake-idea.
digi fuel cups (BBM part #037133555A)
abf front water jacket (blackforest part #EBFIABFWN)
obd1 side water jacket new CTS (blackforest part #226110602)
xflow head gasket (BBM part # 037103383N)
head studs kit (ARP 16v kit this is a must if going turbo)
throttle body adaption from oval to square or adapt the tps (blackforest part #037907385Q)to oval throttle body (obd2 must use adapter) (blackforest part #ESPATBA) have your 16v manifold welded to use the obd1 throttle body
exhaust spacer or extended header not sure if it will work on 16v scirocco manifolds in a mk1 or not? (blackforest part #EBFIMK18VABA) Techtonics has the tall block header for mk1 16v and mk2/mk3 16v
radiator lines combo from aba and 16v
alt kit ABF (blackforest part #EBFIABFABA)
Turbo oil pan (blackforest part #EBFITROP) prep for turbo
custom crank sep pully (BBM part #226101606)
vr6 water pump pulley if no PS/AC (blackforest part #021121031D)
valve cover breather (BBM part #226101739)
modify a 16v distributor from a 1 window to a 4 window (you need the aba dist for parts) This is also a good writeup
Use the factory aba dist intermediate shaft and oil pump by using any of theses caps (EchlinIgnition - EP480,AC Delco - E372C or E392,Airtex - 5D1115,Auto Tune - PT1604,Beck Arnley - 1746847,Borg Warner - C584,Bosch - 03156, 03181, 1235522215, 1235522217, 1235522305,Commercial Ignition - XD227,Niehoff - WA401,Sierra Marine - RB940,Standard - GB427 ) some grinding of the lower part of the factory intake manifold is needed to clearance the sideways cap.
Custom chips can be made by UM,TT,BBM and others, best thing to do is get it running on a factory ecu with all sensors then talk to one of them and have a custom chip burnt to meet your needs.
You must also adapt the ISV and ITS (blackforest part #280130039) from the obd1
The intake temp sensor will need to be installed into the 16v manifold and you must use the OBD1 ISV
There is a pin that lines up the head that needs to be knocked down or the head will need to be slightly modified.
low compression head gaskets for use with 9a and ABA
Different head gasket sizes BFI has 3 different thicknesses 0.90,1.50&3.5 all for 95$ plus shipping
Block off plates
Anyone care to contribute any more good info to this post on how to make a NA low compression 16v aba 2.0 (to be boosted in the future)
EGR valve delete cut pin 10 at ecu (solid white or brown and white count from top left)
Make your tach work
T/28 from your gauge cluster/tachometer it is a solid green wire
T28/10 Tachometer U1/06 Green Green Green
or you can hook - from the coil to (any aftermarket tach)
G1/12 Ignition Coil Pin 1 (all Mk2, most others '90 only), ECU tach signal (all 91+ except Mk2) Tachometer Red/Black (coil) or Green/Black (ECU)
Cheap 16v cam info DIY
Ditch your power steering without swapping racks in a MK2
Great Info here
Now you can get it running and acquire the turbo parts to finish it
turbo and manifold, injectors and chip, inter-cooler and pipe, oil lines, SRI, BOV, Waste gate solid mounts new fuel pump custom down pipe ect ect ect...