Hybrid 2L 16v build!

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Hybrid 2L 16v build!

Postby Krakie on Thu Jan 14, 2010 11:19 am

I think its a good idea to have one well of info for the guys who want to build 16v's especially the hybrid motor of choice: 2e + 16v head. I've done searches and there's not really much topics that can help. So my idea is to make this thread and list the goods needed. I'll make an initial list. It wont be exhaustive but just to get us started. Please feel free to add and I will edit this post.

Head:
16v head from any old age 16v motors i.e. not the fsi motor's head.
Preferably have the head overhauled and replace all the necessary bits. Its a very old head so be sure to do this. So you know what you've got.

Block:
Any 8v long block from the vw range. Preferably one with oil sprayers and steel crank.

Sprockets & Pullies:
All the 16v sprockets & pullies will be needed, that is:
Cam sprocket
intermediate shaft sprocket
crank sprocket
crank pulley
water pump pulley (vr6 or polo aircon delete Pullies also work)
Tensioner

Intermediate shaft:
2 options, either go out and get a 16v one or modify the end where the sprocket fits on the 8v one. more details to follow later.

Oil pump:
2L 16v oil pump you would need to get the gear that turns the oil pump from a 16v (very hard to find)
2L 8v oil pump, leave the dizzy in so that it turns the oil pump, you could even cut the dizzy at the shaft to make it look like a block off plate

Pistons:
If you don't want to bore you can try and get ABF pistons. But that's easier said than done.
Other pistons you can use are nissan pistons, astina pistons, bmw pistons. For the rest i will wait for input from you guys but for now i'll stick to what i know.
The nissan ca18dej/det piston. Yes the turbo piston. its a flat top whereas the n/a piston is domed. This is an 83mm piston So you will be required to bore your block. Also the piston sits 1mm below deck height at tdc on a stock block. This was measured by JVS tuning as well as *cant get to the engineering places name, some help Jody* anyway think it was nme in bellville south.
So best bet is to deck the block.
You will need to pocket the pistons for the intake valves as well.
You can also use aal 2L 16v pistons but they expensive and you'll also have to deck the block. But no pocketing needed.
Oh one more thing, pistons or rods have to be machined in order for the rods to fit into the piston.
And rods have to be re-bushed with aal small ends. that is 20mm bushes where 2e uses 23mm bushes.

Both of the above are for the nissan pistons.

Fuel rail:
Motorcade in montague gardens sell them as well as Motordrive in parow.
If you not running stock manifold a 20v turbo fuel rail will also work.

Injectors:
Many opt for vr6 injectors and there are guys running them without any problems then others recommend that 20v turbo injectors be used. You could also purchase aftermarket injectors.

Clutch:
sachs powerclutch or luk 210mm clutch kit, using the 2e or 1.8 flywheel.

If using the serpentine alternator setup the belt to use is the 6pk900 or if the correct alternator cannot be sourced, you can use a mk1 alt bracket to tension a 2e alternator to the bottom part of the serpentine bracket(will try to take pics) in this case use 6pk975 fan belt.

Timing belt, the abf has a 151 tooth, I've consulted with a few people that have done this build in the past and a 150 tooth X 23mm audi 20v belt is also suitable, powergrip part no. 5491xs. Supey found a belt that is 151 tooth X 25mm that he is using.


That's all for now just to get this started. I'm sure there's alot i missed out on. I'll edit this post and even add pictures when I have a chance.
Current: 2007 Seat Leon FR
Ex: 2000 Golf 4 GTI
Ex: 1994 CTi 2L 16V (under construction)
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Re: Hybrid 2L 16v build!

Postby GT'79 on Thu Jan 14, 2010 1:41 pm

Werk j self op jou kar?
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Re: Hybrid 2L 16v build!

Postby Krakie on Thu Jan 14, 2010 2:19 pm

Here and there but under strict guidance from my old man. And I try to take note as much as possible of what he does. If I do something when his not there he normally takes it apart and does it himself again lol. But ya my hands were not made for this.
Current: 2007 Seat Leon FR
Ex: 2000 Golf 4 GTI
Ex: 1994 CTi 2L 16V (under construction)
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Re: Hybrid 2L 16v build!

Postby Krakie on Thu Jan 14, 2010 2:24 pm

Oh one more thing. Will add it to the list later, pistons or rods have to be machined in order for the rods to fit into the piston.

And rods have to be re-bushed with aal small ends. that is 20mm bushes where 2e uses 23mm bushes.

Both of the above are for the nissan pistons.
Current: 2007 Seat Leon FR
Ex: 2000 Golf 4 GTI
Ex: 1994 CTi 2L 16V (under construction)
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Re: Hybrid 2L 16v build!

Postby GT'79 on Thu Jan 14, 2010 2:26 pm

Krakie wrote:Here and there but under strict guidance from my old man. And I try to take note as much as possible of what he does. If I do something when his not there he normally takes it apart and does it himself again lol. But ya my hands were not made for this.


Oo ok, so you steal with the eye :mrgreen: same with my ou, i just take note
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'78 Mk1 2door GT - RIP Too much cancer-
'79 Mk1 2door GT - New Project
'96 Jetta CLi 2.0L 8v MP9 99.1 KW - 187 Nm with Zorst and Branch RIP
'94 Jetta CLi 2.0L 8V Stock standard (WIP)
'97 Jetta CSX 1800 8v (WIP)
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Re: Hybrid 2L 16v build!

Postby Krakie on Thu Jan 14, 2010 2:38 pm

GT'79 wrote:
Krakie wrote:Here and there but under strict guidance from my old man. And I try to take note as much as possible of what he does. If I do something when his not there he normally takes it apart and does it himself again lol. But ya my hands were not made for this.


Oo ok, so you steal with the eye :mrgreen: same with my ou, i just take note

Ya man, I always do something wrong :lol: but i got zero experience with this stuff so glad to learn a bit here and there.
Current: 2007 Seat Leon FR
Ex: 2000 Golf 4 GTI
Ex: 1994 CTi 2L 16V (under construction)
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Re: Hybrid 2L 16v build!

Postby Pip3R on Thu Jan 14, 2010 3:03 pm

Question:

is there another alternative to decking the block?
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Re: Hybrid 2L 16v build!

Postby pepa on Thu Jan 14, 2010 3:12 pm

Pip3R wrote:Question:

is there another alternative to decking the block?


longer pistons or rods.
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Re: Hybrid 2L 16v build!

Postby Pip3R on Thu Jan 14, 2010 3:21 pm

pepa wrote:
Pip3R wrote:Question:

is there another alternative to decking the block?


longer pistons or rods.

FYI for those who are not keen on decking blocks.
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Re: Hybrid 2L 16v build!

Postby pepa on Thu Jan 14, 2010 3:29 pm

Pip3R wrote:
pepa wrote:
Pip3R wrote:Question:

is there another alternative to decking the block?


longer pistons or rods.

FYI for those who are not keen on decking blocks.


im not a fan of decking blocks or raising compression.
A machine with std comp. tends to be more reliable
in our sport.
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Re: Hybrid 2L 16v build!

Postby Krakie on Thu Jan 14, 2010 3:34 pm

Pip3R wrote:
pepa wrote:
Pip3R wrote:Question:

is there another alternative to decking the block?


longer pistons or rods.

FYI for those who are not keen on decking blocks.

ABF pistons is another alternative. Also you can leave the piston height as is then have your comp worked out. Then remove the 1mm plate from the steel gasket. Depending on the cc of your head this will give you roughly 10:1 compression. I could've gotten 10.2:1 but opted for higher comp so went with the decking.
Current: 2007 Seat Leon FR
Ex: 2000 Golf 4 GTI
Ex: 1994 CTi 2L 16V (under construction)
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Re: Hybrid 2L 16v build!

Postby Krakie on Thu Jan 14, 2010 3:41 pm

Also just an fyi decking the block and running standard gasket will give round about standard comp.

ABF pistons sit slightly above deck at tdc. Don't know by how much though.
Current: 2007 Seat Leon FR
Ex: 2000 Golf 4 GTI
Ex: 1994 CTi 2L 16V (under construction)
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Re: Hybrid 2L 16v build!

Postby Krakie on Thu Jan 14, 2010 3:41 pm

Also just an fyi decking the block and running standard gasket will give round about standard comp.

ABF pistons sit slightly above deck at tdc. Don't know by how much though.
Current: 2007 Seat Leon FR
Ex: 2000 Golf 4 GTI
Ex: 1994 CTi 2L 16V (under construction)
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Re: Hybrid 2L 16v build!

Postby Pip3R on Thu Jan 14, 2010 3:56 pm

Pro's and con's of decking block?
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Re: Hybrid 2L 16v build!

Postby pepa on Thu Jan 14, 2010 4:01 pm

Pip3R wrote:Pro's and con's of decking block?


vra vir King Shuffler.
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