PG to ABA swap notes w/pics

[REPOMAN]

Someone IM me for this so here it is.

Swapping a 1.8l PG g60 for the ABA 2.0l block

The 1996 ABA motors do
not come with the oil quarters the PG block has. so
the machine shop should be able to port the ABA
block for them. new i paid $27 ea for the oil
squarters and $13 for 4 check seat bolts.
I believe the machine shop charged $100 to install.


For the breather I Use the Techtonics Block off plate
And tap it with an oil return fitting.



As for the Distributor if you are using the Digifant
ECU then just swap the 2.0l dist. gear on to the g60
dist. and use the g60 dist. you will need the
adapter ring for the g60 dist. so it fits in the block
then just plug it in and go.

As for the height difference on the alternator bracket that bolts to the head
Just leave the bottom bolt out as shown




If you are deleting the A/C just buy a VR6 water pump pully then reroute the serpintine belt around it.
With the longer stroke of the ABA of 92.8 mm
the 95- and older crank shafts are forged , but the later
models are cast and will not stand a boosted
application. just TAP the lobe of the crank with a
hammer, if you hear a high pitch ring it is a forged
crank. I had mine Knife edged and 3 dowel added for
quicker higher revs and added >strength. recommend having them resized for ARP bolt


>I decided to spend the $$ and get the JE forged pistons,
83mm 8.0-1 comp. Ratio. Well worth the money
And total seal rings.
with the taller block means the
2.0l down pipe will be needed. it just bolts up to the stock exhaust
manifold and cat converter.

The 8 v g60 head bolts right up I recommend using the ABA Head
gasket and if you can find the early Diesel Rabbit head bolts. they are
alot cheaper and just as strong as ARP studs
The key to power is the flow any machine work around the valves and
ports help the counter flow head alot.
<

I also purchased A Modified Audi 5000 intake manifold for more volume 2000cc up from 1800cc

I suggest the BBM adjustable serpentine belt tensioner for ease of fitment


Clearance issues with the audi manifold In the Corrado I had to notch the wiper motor package tray and the hood Support at the throttle body.

I started with the Giac 4 with the stock intercooler
using the Bahn Brenner Lysholm screw compressor at 12.5 psi . it ran real strong but have since Ditched the stock intercooler for a liquid intercooler from Overkill Performance

And the Stage 4 BBM 310cc chip.
Right away it ran a lot smoother at idle, and Pull pull pull with the 272 276 cam it dynode at 192whp and 202wtq so far, with a Tourqe curve that’s starts at 150 wtq @ 1250 rpm and hit 200wtq at 3000rpm and doesn’t drop until red line .gotta love that supercharger.
with 17psi and 310cc @ 8bar it hit 206whp 225wtq @ 2800rpm


The swap has been relatively easy and have yielded great gains. The car is a dream to drive lots of power so a good transaxle is needed. So far I have bumped up the clutch pack for the added power with a VR6 pressure plate and a 6 puck foramic clutch dics from clutchnet.com and a Quaffie LSD
i have also purchoused the Driveshaft Shop stage 3 Spring Torsional Axle for the Hard 13 sec 1/4 mile Launches.
Hope this helps anyone thinking of this swap.

[Strictly Gravy]

pics aint workin. use camo.flage.net

[dubjetta]

what do you guys think of running a turbo on a 2.0 aba block, g60 head.

[REPOMAN]

If you are going as far as a Turbo system on a built ABA Block
then i would defently ponie up the $$$ and go with a 20v head.
Or atleast a 16v head. better combustion chamber design.

[HowManyVWs]

Hey I'm the one that IM'd you. I just wanted to say thanks alot, not only for the info but for your time. I know we all like to post but not everyone is so helpfull, so once again thanks alot and I appreciate all the info. for you!!

[dubjetta]

If you are going as far as a Turbo system on a built ABA Block
then i would defently ponie up the $$$ and go with a 20v head.
Or atleast a 16v head. better combustion chamber design. qoute:

20v head? what are the issues with bolting up a 20v head to a 2.0 aba block. clearence issues, intake ect. would i be able to use my digi 1 managment or would stand alone be the only option? sorry for the bonehead q's. thanks for the info.

easy, chris.

[Mad Turk]

Hey man, that's an awesome post, very informative...
As for fitment issues:
Do you think clearancing would be any less of a problem using the stock intake manifold? Or maybe a VR6 hood, i know there's a bulge in those where the G60 hood has a depression...? Thanks and keep on rockin'
The Turk

[dabongo]

This is greatly appreciated, and give's me some good ideas..

What year of Audi 5000 manifolds are adaptable? I thought they were 5cyl engines....

Thnx!!

[fwdvw]

For the distributor you can also opt for the Audi 80 Distributor or the 2.0 liter distributor from TT (Audi 80 like) for $150 or so.

[Thompson]

Quote, originally posted by dabongo »

What year of Audi 5000 manifolds are adaptable? I thought they were 5cyl engines....

They are 5cyl...but the port to port spacing is the same as the G60 head, so you can machine off the last runner and wled up the gaping hole it leaves... that's how you can use the Audi manifold... and iirc, they are the 5000 Turbo manifolds, but I'm not 100% sure on that...

[Capt.Dreadz]

Im doing the same swap in my wifes car. I spent the money and got Weisco 83mm/8.1c/r. I was gonna go xflow head but i rather use the G60 head.

This is a pic of my ported Xflow head( Next to my ported and soon-to-be polished with new vlaves and such). I dropped the idea of the Xflow( Cause its going on my car) and use a spare head(G60) i had laying around

[Iceman666]

man this posts keeps getting resurected

ok if you got the pistons for an ABA then your all good

there is no change in compression swapping an xflow head with a G60 one, basicly they are the same..sept for the xflow part...duh

and youd better think about that xflow with a G60...intake manny is gonna be a BIATCH

[130_R]

Quote, originally posted by Iceman666 »

and youd better think about that xflow with a G60...intake manny is gonna be a BIATCH

I would like to atleast try

[Iceman666]

Quote, originally posted by 130_R »

I would like to atleast try

what did i tell you about posting in forums you dont belong in!!!!!!!

and you have a tig so its not as big a deal for you

[LooseNut]

If you spend the money on new pistons for this swap. Why not just rid yourself of some head aches and just bore the stock block to 1.9L? What's the disadvantage to this route besides having .1 liters less?

[Iceman666]

the 2.0 block is made to be a 2.0 so its stronger, has better rod to piston ratio's and stuff like that

plus if your boring stuff...why not bore the 2.0 to a 2.1

[Andrew83gti]

actually i believe the 1.9l would be better because of the fact that its not getting a bigger stroke. Its only getting a bigger bore which means more low end torque.

Andrew

[REPOMAN]

Incorrect ...
the longer stroke makes for more low end TQ
my 2.0l hits 150wtq at 1250rpm a pg with similure mods
doesn't hit 150wtq until 2000rpm
as for a stronger motor i believe the PG is the strongest
rods,wristpins,cooling, ect.ect.

[Iceman666]

rule of thumb is bore gives you HP stroke gives you torque

ease of flow gets you HP restrictions give you torque

[zero666cool]

great info