16v engine in a MK1 by paul-c

After toying with putting a G60 into my Mk1, I've settled on getting hold of a 2.0 litre 16V engine (eg from Passat) and 'doing' the 2.0l 16V conversion. Actually I investigated a whole range of engine conversions, but since this is my first one I decided on something which has been done before and has a lot of info 'out there' on how its done, etc.

Anyway, I'm at the 'parts gathering' stage and after a browse around other fora, I found my motor. Only problem was it was 200 miles away! So I headed off with my trusty estate car and 8 hours later, I was back at home with this in my boot:



Its a 9A engine out of a Passat, and included is a box full of all the bits which were attached to it, and a cable change, hydraulic clutch gearbox (which won't be getting used!)

Cool  8)

How did you get it in the boot though? It must have been a tight squeeze with a crane in there as well  8O

Rich

A few more parts have been bought and arrived.

Complete Ashley 2 1/4" exhaust system and 16V conversion manifold, from www.rallydesign.co.uk:



Pair of cams from a KR engine (1.8 16V). Apparently, the 9A engine has a milder inlet cam, no doubt due to having a catalytic converter. So you can simply fit the KR inlet cam and gain a good amount more power. The exhaust cams are the same, but came as a pair from an eBay find:

Right, onto the work proper. Unfortunately, lack of space means that the engine is still stuck inside the car it arrived in, which being a large estate, makes an ideal temporary 'shed'. I've managed to remove the inlet manifold, which looks really grubby and needs a good clean and painting:



The inlet manifold is 42mm internal diameter off a 9A, where some Mk2 16Vs have a 50mm manifold. After a bit of research, there's no point swapping, since the larger manifold loses torque and power through almost all the rev range and only adds 1bhp right at the top.

Anyway, onto cleaning it up:



Its a bit hard to see but around a third of the surface is now cleaned up. At this point, I lost the will to carry on with it, its a slow job!

To be continued…..

mcscrew said

Cool  8)

How did you get it in the boot though? It must have been a tight squeeze with a crane in there as well  8O

Rich

It was split from the gearbox and 4 of us lifted it, with no real problems! I saved the bother of having to take a crane with me on the long journey. In any case, you can easily fit an engine and crane in the back of my car, you can turn the engine so its in-line and it all fits nicely.

The only downside was that the seller hadn't removed the oil (I suppose there's an advantage there, it means a lot of the internal components will be covered in oil and not corrode, etc) so I had to tie it in the vertical position with washing line and make a 200 mile return journey with the engine jiggling in the back of the car.

wicked im gionna be watchin this one!!
congrats paul.

Best engine i rekon.
I have a g60 in my c and prefer the instant power you get from the 16v.
Just wish I had the patience to make her all shiny before I got it put in.
Your going to love it.
Still waiting to get some KR kams fitted to mine

First conversion, sounds like me, lol

all looking good paul!  Good luck with it   :y:

Well worth sliding those KRs in  

looks good! inlet is shaping up nicely! happy polishing! 8)

Nice one, Paul.  I'm doing more or less the same with mine at the minute.  Is the engine you will be running for the track day at Snetterton?

Great pics mate, doing a resto and 9a conversion at the moment too,

MatCashmore said

Nice one, Paul.  I'm doing more or less the same with mine at the minute.  Is the engine you will be running for the track day at Snetterton?

Realistically, I'd never get all the work done before the track day at Snetterton, so I'll be doing that with the current (standard) engine. I could probably get it in and running, but I want to take time and clean up/paint all the little bits, plus neaten up the engine bay too, while the engine is out. So straight after the track day, I'll be taking the old engine out and getting stuck in proper.

With the number of parts which need cleaning up and painting, I suspect there's more than enough to keep me busy in the meantime…

Looking good so far. How much did the engine set you back? I'll be keeping an eye on this as I fancy doing this myself somewhere down the line… Quite fancy a 2.0l 16v G60 on megasquirt! Hmmmm!

woZa said

Looking good so far. How much did the engine set you back? I'll be keeping an eye on this as I fancy doing this myself somewhere down the line… Quite fancy a 2.0l 16v G60 on megasquirt! Hmmmm!

The engine cost ?300. I know some people have found 9A engines for cheaper, I think some of that's down to luck, and the lower you go on price its always possible that the engine you buy is junk. That included a big box of other parts, such as starter motor, alternator, water pump, gearbox, etc etc so I can recoup some of the money by selling off unwanted stuff after I've worked out what I need to keep.

People have done turbo conversions on the 16V, obviously starting with a 2.0l over the 1.8 can only help here. I've not heard about anyone doing a supercharger conversion. Hopefully I'll be happy enough with the 160bhp or so of the stock-ish engine - I'll only really be swapping the cam and using a big exhaust (and obviously decat).

Well it looks like this is one popular swap !  Had a look round the local scrappy last weekend and came home with this :



A 2.0 16V 6A engine out of an Audi 80 and is destined for the Caddy (at some point - I'm not a fast worker !)

What miles has yours done Paul, and are you going to take the head off and have a look or just run it as is ?  This one's done 123,000 so am a bit unsure whether to throw it in or do a bit of a rebuild. I couldn't run the engine at the yard as some other stuff missing from the car and they empty fluids out anyway. Car had been rear-ended, so good sign of why it was scrapped (ie, not duff engine - I hope). Checked the plugs which are a bit sooty (bit black, but not oily - rich mixture problem methinks). No 'mayonnaise' in the rocker cover. Hmmmm, unsure what to do. Was very cheap so thought I'd take the risk.

Picked up inlet manifold, engine loom / "ECU", metering head and lines from a 1.8 Corrado 16V they had in. Think I'll have to go back for the sump and oil pick-up.

If you get time I'd be very interested to see a pic of the front of the block around the oil filter housing. I know I have to change this, but was wondering if the 9A has a breather outlet on the block above this as mine does.

Good luck with it and keep us posted !

Cheers,

Mark

paul_c said

Realistically, I'd never get all the work done before the track day at Snetterton, so I'll be doing that with the current (standard) engine. I could probably get it in and running, but I want to take time and clean up/paint all the little bits, plus neaten up the engine bay too, while the engine is out. So straight after the track day, I'll be taking the old engine out and getting stuck in proper.

Fair enough.  You might as well get it right, rather than rush it.    

What brake set-up are/will you be running? They're the parts I'm having most problems sourcing at a reasonable price!

MatCashmore said

paul_c said

Realistically, I'd never get all the work done before the track day at Snetterton, so I'll be doing that with the current (standard) engine. I could probably get it in and running, but I want to take time and clean up/paint all the little bits, plus neaten up the engine bay too, while the engine is out. So straight after the track day, I'll be taking the old engine out and getting stuck in proper.

Fair enough.  You might as well get it right, rather than rush it.    

What brake set-up are/will you be running? They're the parts I'm having most problems sourcing at a reasonable price!

I already have a 9" servo and 22mm master cylinder conversion. If it proves not to be enough, I'll look into aftermarket 239mm discs and pads. I really want to try keep at 239mm, because I want to keep the 9 spoke (13") alloys. But if I need to upgrade to bigger discs, I'll search around for some decent 14" or 15" wheels too.

well to add on, my 2L 8v coming out and im putting in a 2L 16v as they are cheap, but this time im not attempting it, i dont have the room or pateince anymore, so getting a garage to do it this time.
Still saving so will do pics when its on its way a bit more.
Love to see peoples pics as its progressing, keep posting them

m6m62 said

ing. I know I have to change this, but was wondering if the 9A has a breather outlet on the block above this as mine does.

Good luck with it and keep us posted !

Cheers,

Mark

yup, there is

Ah, nice one - thanks for the pic !