16v FAQ: if you are new to the 16v forum, this is the thread for you

[AtariMasta]

Wanna know the nitty-gritty about rebuilding a 16v? Check out my website, I update it often.

http://www.marshallplan.org

-Luke

[dbpulvino]

Don't know if this has been posted yet, but the part number for the Generic (Ford) O2 sensor is 13913. Can be found at most any auto parts store (in my locale, Schucks for example), and should be quite a bit cheaper than the factory or VW equivalent.

I believe this comes from a Ford Mustang and/or an Escort.

hth,

Derek P

[ValveFloat]

Cams
I thought I'd post this since there are often questions about aftermarket cams for the 16v, although I don't know how useful the info in this article is. If you look at the graphs, some of them don't look right. They must have remade the graphs to make them look better or work better for printing or whatever. Anyway on some of them it looks to me like the got confused as to what part of the curve was torque and what part was power. On page 3 the 2nd graph shows this; before the curve for the Kent 258s cross it looks correct, but after they cross the pink curve should be torque and the red curve should be power. Remember when looking at a graph that uses the same scale for power and torque the curves must cross at 5250 RPM. Although it is not mathematically impossible for the curves to cross twice, if the torque curve was rising like the red curve the power curve would be rising even faster, it would not be flat like the pink curve. All the graphs except the baseline are messed up in this manner. Well anyway here is a link to the story:
European Car 16v Cam Test


Modified by ValveFloat at 10:55 AM 5-6-2003

[ValveFloat]

quote:

---

Don't know if this has been posted yet, but the part number for the Generic (Ford) O2 sensor is 13913. Can be found at most any auto parts store (in my locale, Schucks for example), and should be quite a bit cheaper than the factory or VW equivalent.

---

Don't know if the Ford one is cheaper than this, but this seems like a pretty good deal.
O2 sensor from Adirondack


[Modified by ValveFloat, 11:55 AM 3-7-2003]

[Phobia16V]

This came up in a thread recently, and I think it will be useful as a part of the FAQ. A comparison of different 5th gears vs. final drive ratios, showing their respective RPMs at higher speeds:

(Stock 16V)3.67 R&P, 0.89 5th =

3715rpm @ 70mph
3980rpm @ 75mph
4245rpm @ 80mph

Top speed(5th gear x R&P x 6000rpm) = 117mph

(4K)3.94 R&P, 0.85 5th =

3809rpm @ 70mph (+94rpm)
4081rpm @ 75mph (+101rpm)
4353rpm @ 80mph (+108rpm)

Top speed(5th gear x R&P x 6000rpm) = 114mph (-3mph)

As you can see, the difference in RPM is negligable, and will still allow for passing without downshifting to 4th.

(4K)3.94 R&P, 0.80 5th =

3585rpm @ 70mph (-130rpm)
3841rpm @ 75mph (-139rpm)
4097rpm @ 80mph (-148rpm)

Top speed(5th gear x R&P x 6000rpm) = 122mph (+5mph)

[allan r]

i rememeber them saying the dyno graphs were misprinted. either way a good read

[danny_16v]

Camshafts

Always remember the Timing of camshafts when installing/removing camshafts, the timing marks are timed by aligning two dots on the left face of the sprockets. If you cant see the alignment marks or their off alignment check your engines TDC.

I had trouble with this when my head was rebuilt, the camshafts where placed out of alignment.

[impulse byer]

someone said that you could run two exh. cams dose is this make any more power or what.i have a extra set of stock cams if its worth any power ill try it

[danny_16v]

yes you can, you have to do some cutting I beleive, search on the first page of this forum.

[impulse byer]

the

quote:

---

yes you can, you have to do some cutting I beleive, search on the first page of this forum.

---

the link dosn't work can someone help me with this sence i have the parts already

[Instigator2]

Wow, excellent thread guys! Thanx for all the input from all you "Guru's"!
This was just what I was looking for.
I just bought my 5th VeeWee and am taking delivery tomorrow.
It's a '88 16V Gli 5 speed.
pretty solid but definately used as a beater in her earlier life. But, that's also why i got it for $1200.
Two questions for you.
#1. valve/lifter noise on the 16 valves. I had a 16v GTI that did ir and so does the car I just bought. Two shops (VW shops) told me this is common and not to worry about it. One problem, I HATE LIFTER NOISE!!
Is it a cheap fix??

Question #2 is in regards to gas.
As I recall, the owners manual for my '91 2.0 16v GTI I had said you can run what ever you wnat for octane but for max perf. run hi test. I think I remeber "feeling" drastic differences between the two.
With gas prices what they are now, can I run poop gas if I'm not beating on the car, i.e. trips etc??
Thanx again guys, great thread.
Gary

[Ted]

the motronic engine management will retard your engine timing via the knock sensors if you run low quality gas under hard driivng where engine heat builds up. You will just lose overall power but you will be saving your engine from melting down...you should however use at least 91 octane for a good complete combustion due to the 16vs high revving and high compression nature. I know gas prices suck these days but if you want your car to run at its best, you just gotta pay the extra price ... just don't drive around as much if you can

[Jett'in]

A G60 downpipe will fit a 16v.
I bought one and it bolts up just the same.
I am adding this b/c if you have a cracked and/or leaking downpipe, the G60 ones you will find for sale have lower mileage on them and are usually in much better condition than the used 16v ones.
Good luck!

[H2Zero]

If Motronic engine can be chipped, Is there anything you could suggest for Jetronics to increase its BHP....../

[Phobia16V]

Quote, originally posted by H2Zero »

If Motronic engine can be chipped, Is there anything you could suggest for Jetronics to increase its BHP......

http://www.jetchip.com/

[130_R]

spring cleaning, continue on

[rockin16v]

rebuilding a 2L 9A block?

Here is the list of parts you'll need for a full rebuild. a lot of these are reusable, but here is the list:

magnafluxed (checked)
hot tanked (cleaned)
resurfaced
honed (92.8mm)
Rod bolts (ARP recommended) - OEM are one-time use stretch bolts
crank rod journals being machined (if new rod bolts used)
crank main journals being machined (if new rod bolts used)
rods machined and balanced
pistons glass beaded
new rings
new frost plugs (4)
new aux shaft bushings (metal ones that have to be pressed in)
new front/rear seals
new front rear gaskets
new rod bearings (one over)
new crank main journal bearings
assembled short block
polished oil pump shaft gear cap
painted gloss fire red.
new oil pan gasket
2L oil squirters
2L 9A 144mm balanced 16v rifle drilled rods
oil pan cleaned and painted gloss black.
new dipstick tube seal
new oil filter to block gasket
new ring set (2L)
new low-temp thermostat (170°C)
new alternator belt (custom size)
new power steering belt (custom size)
new coolant hose (small one)
new oil filter (bosch)
new oil (10w30)
new coolant
new VW OEM themostat o-ring
new VW OEM timing belt
new VW OEM timing belt tensioner
new VW OEM intermediate shaft o-ring (green)
new VW OEM coolant level sensor
new VW OEM coolant expantion tank
new VW OEM coolant hose (big one)

[rockin16v]

rebuilding a 1.8L PL head?

Here is the list of parts you'll need for a full rebuild. a lot of these are reusable, but here is the list:

cleaned
ported and polished (intake aggressive, exhaust mild) (optional)
shaved 0.015" to bump compression to 11.0:1 (optional)
stage II intake cam 276° (optional)
stage III exhaust cam 280° (optional)
new valve seals (16)
new exaust valve guides (8)
3-way valve grind
assembled by machine shop (valves)
new valve stem seals (16)
new throttle body gasket (both)
new intake gaskets (upper and lower)
new valve cover gasket
new inner spark plug gasket
new cam seals (left and right)
new cam chain
44mm intake manifold (part #027 133 223 AF)
port matched intake/to gasket and head to intake (recommended)
new VW OEM distributor
new VW OEM Hall sender
new VW OEM bosch cap
new VW OEM bosch rotor
new VW OEM head gasket (2L)
new VW OEM temperature sensor (2)
new VW OEM stretch head bolts (16)
new VW OEM water temp sending unit
new VW OEM bosch 4 tri electrode plugs
new VW OEM oil pressure switch (0.15 bar)
new VW OEM oil pressure switch (1.8 bar)
new VW OEM allen bolts
new VW OEM oil breather gasket
new VW OEM fuel injector seals (8 -4 thin & 4 thick) - 1 of each on each injector

[rockin16v]

and here is what to do with all those parts

[r4r3f0rm]

The fuel pump for 1987 - 1989 16v differs from that in a 1990-92. The Jetta's 16v fuel pump is different from the 8valve and the 16v pump from a scirocco. The prepump on 16v's (intank fuel pump) are accessible without dropping the fuel tank. But no matter what you do... you will smell like gas for a week or two.

[Action Jackson]

Quote, originally posted by Jett'in »

A G60 downpipe will fit a 16v. I bought one and it bolts up just the same. I am adding this b/c if you have a cracked and/or leaking downpipe, the G60 ones you will find for sale have lower mileage on them and are usually in much better condition than the used 16v ones. Good luck!

Interesting. Does the G60 dp offer better flow too? Or the same? Would this be a cheap mod for power gains?

[Jett'in]

It is just a direct replacememnt for the 16v.
As far as I know it is the same size and should flow the same

[ValveFloat]

How to remove AC.
Golf/Jetta II FAQ page 4 towards the bottom.

[Space9888]

Just to Make things a little clearer for anyone who is building a 16v or those of you who forgot to mark the pullies before pulling the timming belt off.

the "dot" on the flywheel shown above is the reference for timming the crank to the cams (as stated zero degrees TDC)

the "hash" mark on the flywheel is a reference for ignition timming (6 degrees BTDC).

Be sure to use the "dot" on the flywheel to time the engine (crank to cams) not the hash mark as this will make a mess of your valve train.

[mullet92]

If I got a new 1.8 16v intake mani and tb 42mm
What would I have to do to fit it to a 2.0 16v???
New to 16v engine and forum soo help me out

[MKIIKenneth]

this is my first project car and i am new at this. i've tried posting other places and haven't gotten much help. i have a few questions.
1) how can i find out the year of my engine for parts?

2) oil dripping onto the exhaust manifold and burning off in a cloud of smoke, but only if i use the clutch or use reverse alot when i drive it. How can i fix this?

3) alternater drivebelt and/or bearings screach when in a low gear, stops when the engine goes above 3000 RPMs. What is it, how can i fix it?

I would appreciate the help, i have only dabbled in the home mechanic thing for a short time know.

[BubbleBLOCK]

Fuel Enrichment Module
Here is how to make a Fuel Enrichment module for those with CisE
Quite detailed with pics: http://forums.vwvortex.com/zer...age=1

MKIII Alternator/Serpentine Swap
Here is how to retrofit a MKIII alternator and serpentine design
Very explicit with detailed list of parts needed: http://forums.vwvortex.com/zer...20530


Modified by BubbleBLOCK at 7:32 AM 9-3-2003

[rockin16v]

Option 1) TT repair kit ($100usd):
http://www.techtonicstuning.com/images/parts/253.001.jpg

Option 2) TT race downpipe (loud)($250usd)::
http://techtonicstuning.com/viewpart.asp?partnum=251.203S

Option 3) TT Downpipe to weld on OEM cat ($125usd):
http://techtonicstuning.com/viewpart.asp?partnum=251.225

Option 4) cheapo replacement part ($136 usd for dp and cat)
http://forums.vwvortex.com/zerothread?id=1104392
http://www.discountconverter.c...30091



Modified by rockin16v at 9:58 AM 6-18-2004

[rockin16v]

OEM stretch head bolt torque specs

10-4-2-6-8

7-5-1-3-9
front of engine

and the torquing is : 30 ftlbs, 43 ftlbs, then 1/2 turn or 2 1/4 turns. Torque everytime following the bolt pattern above.

[Lord_Balsac]

Finding your ECU number (needed for ordering a performance chip) 1990-92 2.0L 16V Ke-Motronic

-Remove Plastic Tray located between engine and windshield (driver side)
-Slide the two wire harness's off of the ECU mounting bracket
-Using a 10mm Socket (with medium extension) remove the nut securing the ECU to the car (dig through the leaves!)
-Slightly Lift and slide the ECU foward; out of its two white mounting clips
-Turn it over
-There is a Bosch Part number and an ECU number (should start with an 8)
-Write the ECU Number down and Go order your freakin CHIP!

[H8SV8S]

Here's a link with plenty of Dyno tests by the UK lads. It's a great way of comparing what mod does what, with a lot of focus on camshafts and 2.0 bottom end swaps:

http://gvk.altrezia.com/

[jbmolly]

OK Guys new to this VW stuff heres what i got and what I know abou it.
1987 Scirocco 16V: Things i know it has.
1. Eurosport header with 2 1/4" exhaust with 2 chamber flowmaster
2. K&N airfilter
3. it has a tag on the pan in front of the radiator that has neuspeed cams installed on it and has 2 #'s and says to tune to factory specs.
has what looks like braided steel fuel lines??? is this stock?
4. short throw shifter
5. tokico adjustable shocks and h&r springs
6. Neuspeed strutt tower brace (front and rear)
7. aftermarket sway bars underneath
Things i would like to find out.(I know almost imposssible without tearing apart or asking previous owner)
if it has upgraded fuel system(is there a way to measure a fuel rail or anything)
what size throttle body( is there a way to tell what size by a part number?)
how much wheel horsepower? does anyone know where a dyno is around charlotte area
I know this car is super fast and handle like it's on a rail.
Thanks for any help. Brian

[adrnlnjunki]

im new to the vw's. when i replace the timing belt what do i do with the alignment of the intermediate gear or does it even need alignment?

[VDub2625]

Quote, originally posted by Bentley, 3-14 »

Note: It is not necessary to time the intermediate shaft on 16-valve engines.

[rs4-380]

Pin numbering for Harness testing.

With the row of 18 pins on top (or the cable coming out of the left side of the connector)

top row 1-18 left to right
bottom row 19-35 left to right