MK1 Golf 16v ABF NOW RUNNING!

Hi , I managed to pick a 2.0 16v ABF Lump  with box etc , loom etc for ?100 . I've done a KR 1.8 16v Conversion into my old mk1 cab a few years back  with no issues , but I hear the ABF lump is about 16mm Taller, has anyone one else here installed the ABF lump in thier mk1? If so , did you encounter problems with the installation

Thanks in advance

I'v also heard there is clearance issue between throttle bodie and the bonnet

Not so if you wack some carbs or itb-s on

But there is also issue with manifold and downpipe as they will sit higher up, maybe 15mm if i remember correctly

good luck, should make a nice car

Standard 16v conversion manifolds don't fit as they are not long enough. I believe you can buy a manifold specifically for the Tall block conversion, though I have no idea where or how much.

If you are good with a welder you could always modify one?

Hi  I've just noticed the supersprint manifolds use a  slip on type sleeve as part of the downdipe  , So I may be able to get away with using one of those.

I Might do a  step by step ABF into mk1 section .. as I've started already

Hey Dude! Im doing this conversion and yes, the supersprint manifold will allow you to put this engine in. Its that or a club hammer on the chassis! 8O . The k-jet throttle body can foul the bonnet but what i am doing is fitting the full abf management to go with it which uses a different throttle arrangement and free's up more space betweem the bonnet and engine.

What gearbox you using? I' sticking with the rod change myself.

vw_singh said

Hey Dude! Im doing this conversion and yes, the supersprint manifold will allow you to put this engine in. Its that or a club hammer on the chassis! 8O . The k-jet throttle body can foul the bonnet but what i am doing is fitting the full abf management to go with it which uses a different throttle arrangement and free's up more space betweem the bonnet and engine.

What gearbox you using? I' sticking with the rod change myself.

Hi mate   I'm using the whole ABF setup injection , ecu etc.  and the rod box…  the mk1 clutch looks pretty small compared to the 16v one. would have been nice to use the mk3 box but I cant be bothered buying extra mounts etc plus  i'm on a bit of a budget. I heard tilting the engine back slighty helps clear some space… well we'll see

I've stripped back what I dont need off the 16v  engine like the stock zorst manifold ,PAS and Aircon pump , and purchased a new cambelt, altenator belt , and oil filter.. might as well while its out..

I got the mk1 engine mount on all ok ,  I had to remove a metal guard by the cam cover to allow me to bolt on the  engine mount to be bolted on but thats about it.

Managed to get the lump in the car last night.. well just about … held in by the top box and drivers site mount. So tonight I'll  get it bolted in propperly.. then start and hopefully finish the wiring on the weekend , ready for me to fire it up.

I've done a KR into a cabbie before so i sort of know whats going on.. but I hate wiring.

I didnt know there were two types of ABF 16v's  one with AC and one without… .. as the pulley arrangements are different. I think I might start adding pics soon

I'm actully looking forward in driving it…. should be fun with 150 odd HP .. I suppose the supersprint manifold will free up a few HP too



While

Kewl! Your getting stuck in nicely. You'll probably find you ill have just over 160bhp by the time your done. Get it to stealth for a re-chip and you'll be rewarded with just over 180bhp and 160lbft torque! No Kidding!

Regards to the gearbox, I'm using a 1600 gti box that i fully rebuilt with a quaiffe diff too. But im using a helix organic friction plate. Use a mk2 gti flywheel with a 210mm mk2 8v gti clutch kit and you will be fine. Just make sure the pushrod seals on the gearbox are good before bolting it up. Oh, you already fitted it all havent you?

Are you wiring up a relay for the hated lambda probe or not? There is a relay control connection from the ecu for this.

Gurds

I'm gonna try and get away without usingg it .. if the ecu gets funny I'll have to use it.. . I'm not sure what other people have done…  I assume they just bin it?

What, bin the lambda all togther? If it does work ok, you will probably get very crap fuel economy. Im deffo gona fit it.

vw_singh said

What, bin the lambda all togther? If it does work ok, you will probably get very crap fuel economy. Im deffo gona fit it.

It'll have to stay on in that case then..

Just done another stint on the mk1…

Managed to get the engine bolted in all ok …. It looks like the bonnet shuts fully ok … some people mentioned clearance issues?… seems all ok here!

Anyway , bolted the stock servo and master cylinder back ok and it all fits in a treat with no modifications..

I did notice that alternator belt tentioner fouls the chassis leg slighty, So i'll manipulate it a little so it fits in nicely.

So the engine is in .. so it looks like the wireing is next…. luckily the breakers gave me the cat which had the lambda probe , so i'lll  cut that out on the weekend and weld it in into the superprint manifold.

I noticed the throttle cable will need to be changed as the mk1 cable is different to the ABF item.. any ideas which one to use?

Tom I'll refit the Radiator and maybe start on some of the wireing oh joy!!

more to come…..

Mate, do the guide, I'll add it into the 16V FAQ i've been sending out to lots of people, at the moment it only covers KR/9A/6A.  And hopefully get it all into the tech section on here now i'm an editor  :wink:


Good luck with it, sounds good so far  :mrgreen:

Im not 100% sure on this but buy a mk3 16v cable and have a look to see if the pedal end is the same as the mk1 item or not. When fitting the k-jet version, you have to use a 16v cable and some bending of the peasal itself to make it work fully. So it may be the same for the ABF.

Oh, and dont weld the probe into the manifol itself. Weld it into the link pipe after the spring bolted 2-hole flange.

Sorry about the deley .. I've had to work out of the country for a while.. interupting my engine conversion  

anyway … heres a pic of where it fouls on the chassis leg . .not a big problem just needs a little  adjusting  




here's a picture of the ABF Cat that i'll be cutting the probe from and rewelding it into the supersprint system I'm waiting for



Will update you a bit more tommorow .. but i've been dragged away to my mates for his B-day

I'm gonna do a full step by step with pics.. including the wiring

Legend  8)

Do it in Word and wack it all in a zip, i'll add it to the Tech section with my 9A/KR faq.  rather that link to images that will dissappear at some point off the web.

looks like its going well!  :mrgreen:

The Supersprint turned up today from germany    It quite a nice exhaust , It looked as if it was standing for a little while so i gave it a spray over with some high temp paint.. its not rusty at all.. only on the bolts whats expected. As I'm fittin the ABF lump and its 16mm taller , unlike the Ashley manifold.. this can be extended to compensate for the extra height of the 16v block. I just need the extra pipe (where i will weld in the lambda) available from supersprint.. only ?30.  As soon I as I get that I'll crack on and try and get the thing fired up..


I havnt made any more progress on the wireing side.. I've just been spending time  tidying up the engine bay… Connecting the speedo drive clutch calbe and various different parts.. .Takes alot longer than I first antisipated! Oh well!!

Hope you liek the pics.. more update to follow (when I have spare time!!)







Rocco 16v manifold… It should fit the mk1 OK .. only time will tell



The supersprint has a nice collector in the end that divides the gasses to promote uninterupted gas flow which is nice.. the Ashley version doesn have this if i can remember

Hi,

Good luck with the conversion, definitely well worth the effort! I have the same set up in my mk1 so thought I would pop down what I have done to mine in case it may be of some help



I've had mine in and running since last August and couldn't be happier with it. I have the ABF fitted with the full motronic ECU which was remapped up at Stealth. The engine is pretty much standard bar the exhaust and manifold and an airfilter (which I hope to replace with something along the lines of the BMC CDA when finances allow). I had the car put on TSR's rolling road back in Feb this year whre it made 193bhp at the flywheel - so not too bad 8O

When I fitted the engine (using a standard 16v conversion manifold) the exhaust used to reverberate underneath the car on overrun, I've since had Storm Developments in Aldermaston reshape the manifold so that it would clear the underside of the car which has made a world of difference!

I'm currently running the ABF with a mk1 8v box, lightened flywheel and standard clutch, however this clutch does slip a little with quick changes between 3-4th and 4-5th. I now have a hybrid 8v/16v clutch to pop in which should sort the problem once and for all.  Having seen Gurdip's acceloration times I've also sourced a 1600 GTI box which I hope to fit with the new clutch… unfortunately I can't afford a LSD at the moment.

Great!! I was gonna ask you how much of the loom you used? I'll take a picture of  what I have and maybe you could shine dome light on it.

cheers

Unfortunately I havnt done any more wiring , but I have discovered I have all the loom etc .. but realised I have a late ECU with inbuilt immobilser.. damm..

so…… I 've been busy finding part numbers and ecu's etc… anyway luckily I have a complete SEAT 2.0 16v so I'm able to test a few ECU's to see if they have the built in immobilser by removing the ring around the Barrel and starting it up with the new ecu in situ.

So far I've tested 2 different part numbered ECU and  I can confirm that they both have in built immobilsers in … one was a 98 ecu and the other a late 95 ecu…. with both the car would fire up for about 0.5 Secs and just stall… like the fuel has been cut.


 this one I just recieved this morning is an early 94 ECU So fingers crossed it will fire up in the car. I'll know tonight when I plug it in.

Anyone have any idea how much power this might produce?

The engine in the mk1 is standard apart from cone filter, supersprint 4 branch and a chip.

I'll be happy if this works!!

wish me luck!!

Hey Guys, been a while. How far did you get with the wiring?

The immobilised ECU requires the transponder unit and key with the maching code to the ECU being used. Otherwise the car will start then cutout after 1 sec. If you can get this far then its a case of getting the ECU and key programmed to have the same keycode.

Gurds