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[rockinveedubs]

So since ive had the car ive been wanting a 16v 9a for a lng while to replace the dead JH i have sitting in my car. And alas... i found one...
So here are my plans...

Rebuild 9a
Botom to top new bearings, seals and gaskets
Timing belt set
diesel motor and tranny mounts(stiffer than stock petro mounts)
scirocco intake (already installed)
stock CIS basic (need knock box, knock sensors, intake boot... already have fuel line from scirocco)
A/C rad for better cooling
Raceland header
Custom side exit exhaust

Close ratio tranny
With taller fifth gear

Suspension
new bushings, strut bearings etc... (already have
raceland coil overs
mk2 front "k member" (already own)

Brakes
Scirocco 10.1" front brakes (already own... need rotors, rebuild kits and pads and powder coating red)
Mk2 rear discs ( have calipers, hubs annnd... thats it.. need bearings, and everything stated for feont breaks and e brake cables
22mm MC and booster with pedal assembly ( would like one from a mk2 scirocco)
P valve (possible aftermarket to custom set brake bias)

Wheels
BMW Bottlecaps powder coated black (already own)
Wrapped in 185/45or 50/14

Body
Factory alpine white (respray andbody work)
Euro bumpers (already own)
Engine bay minor shave (remove junk i dont need and get rid of seam sealant and respray)
Wire tuck
Relocate battery to the spare tire well
Volvo "cold air intake" with custom box to route cone filter in place of battery box. (May have soon)
Little or big duckbill
GTI fender flares

Interior
Would like a mk2 redline 16v dash swap
Recaro fronts

If anyone has any input or could help supply me with parts i have listed or may need let me know. I could use help finding some of this stuff.

Id post pics but my phone is jpeg... but let me know what you think

[rotundapig]

I'll have an o2j with some close gears for sale soon. Putting a tdi 'box in mine. Got sick of there being no traction in 1st

[rockinveedubs]

if it comes with everything for the swap id do it...if the tranny isnt a rediculous price. i dont want to hunt for parts to convert. whats the price? PM me

[rockinveedubs]

So for transmission i want an 02a and brake master and booster from a b3 passat. I keep  hearing different things about how much is involved. Needing a clutch cable from a honda crx and some other stuff from a eurovan... i think thats all cause people half ass it. If i use everything from a passat all id need is conversion mounts. Am i wrong?

[0dd_j0b]

If I can make a comment about side exit exhaust. I had one at one point in the Scirocco, and (It's been a long time since I have looked under a rabbit) but the only way to do side dump without putting your exhaust right on fuel lines, is to dump right between the driver side door, and the read d-side tire, and there is not really any room for any decent silencing muffler, and I will guarantee noise headache's with the exhaust being right there. That is just my experience though.

[rockinveedubs]

Haha dont i know. Ive run side exit with a 2 in exhaust with my JH! I loved it. But yes... very loud. I may get something to quiet it down. Not sure what. May even just get a TT exhaust...

But ive got all my tranny stuff from UPAP! Transmission, shifter, cables, slave cylinder, flywheel, master cylinder, brake booster pedal assembly and engine harness. Got it all pretty cheap. Now i need to build my 9a...

[rotundapig]

side exit exhaust on my rabbit was fun, but very loud. Eventually got ticketed.

[rockinveedubs]

Very! Does anyone prefer a company to buy 9a rebuild parts? Headgaskets, head studs, engibe seals... etc

[rockinveedubs]

Im aiming for building the motor so i can boost it later. Any suggestions on what i should improve over just the building the motor factory spec?

[0dd_j0b]

gaskets and seals and such you can go to GAP.com or bapgeon, something like that.

[rockinveedubs]

Any name brands i should look for? Bap likes to just hand you whatever they have.

[0dd_j0b]

Not really, I haven't had any problems with any gasket sets from GAP.com.

They have head gasket kits includes head gasket, exhaust mani gasket, valve cover gaskets and such.

But yeah, I have not had any problems, and have not heard of anyone else having problems.

[rockinveedubs]

Sweet thanks man. Any suggetions for building the motor for boost later?

[0dd_j0b]

Not really, I'm not very familiar with anything turbo building. When I had aspirations for turbo I looked around for some info and, (please correct if I'm wrong) you are looking for a 8.5:1 compression ratio, not sure what the 9a starts at. Also what fuel management system you are going for, whether Digifant, CIS (please no) or megasquirt, From the plethora of turbo build threads on the whoretex, most people go the megasquirt route for the simplicity of tuning...or something like that. As far as the parts like valves, pistons etc. etc. I am not going to venture into that dark room, cause I honestly have no knowledge, and do not want to make myself look like a tool by talking about something I have absolutely no idea what I'm talking about.

Looking forward for the rest of this build thread, good luck on the build.

[rockinveedubs]

Thanks man. Does GAP stand for something? Im unable to find it

[SwiftMKIII]

Www.germanautoparts.com

[rockinveedubs]

So my plans for the build have been changed. I dint want CIS basic... i will use it but as long as the car is getting all the best treatment id like to use a different route... megasquirt maybe? Im building the car to withstand turbo when that time comes and id like to be able to just bolt on turbo and tune the motor for it. Could anyone give me the basics of what would be needed for some sort of stand alone system? I know I'll have to build my own grom random parts. But i want it done right with good stuff. I dont want to have to back track and redo something.

[0dd_j0b]

DIYautotune.co m  <--- megasquirt needs\

ALso talk to Chris (Smokestack(I think)) and Theron (Random_Task) with everything you need to know, I'm pretty sure there are a few others on here that know how to work on it, but I'm not sure who they are.

[rockinveedubs]

How much does a mega squirt system usually cost? Ive seen from $1200 to $1500

[rotundapig]

Hell no! Build it yourself for like $150 and then you'll get a better idea of how it works:

http://www.diyautotune.com/catalog/megasquirt-kits-c-27.html?osCsid=cc01ba840002eab86bc90301b94763de

[A2GTUS]

I know I haven't been around in a while..but the advice for your turbo build...You might want to drop the 9a block and go with early ABA from what I gather they are forged bottom end...great for boosting...if not then I would get at the very least forged pistons for the 9a...if you just do a standard rebuilt on one the compression ratio is to high (somewhere around 10 to 10.5 to 1)and if you are going to boost the 9a of course get rid of the 2.0 head and find a 1.8 head(better flow..)
When I had my mk2 golf gt I did ALOT of research on how to build a 16v for boost..And I know everyone puts  down CIS because you can't tune it easily...but with the right parts(mostly volvo 240 turbo parts)you can get a CIS turbo'd 16v to scream...

Anyway thats my 4 cents I guess...and just so you know I am not some ID10T(idiot)I was an auto mech for 20 years and have worked on just about evey make and model of car you can think of...with the exception of say a ferarri or bently(well I did do the brakes on one once)...

[101stvet]

I'm prob gonna do a ABA in my mk1 and then S/C or Turbo it later down the road.... A shop here in AZ has pre-built harnesses for this swap built allready...So i'tll be a quick and easy swap...Unless i go the TDI route not sure yet...

[rockinveedubs]

I know I haven't been around in a while..but the advice for your turbo build...You might want to drop the 9a block and go with early ABA from what I gather they are forged bottom end...great for boosting...if not then I would get at the very least forged pistons for the 9a...if you just do a standard rebuilt on one the compression ratio is to high (somewhere around 10 to 10.5 to 1)and if you are going to boost the 9a of course get rid of the 2.0 head and find a 1.8 head(better flow..)
When I had my mk2 golf gt I did ALOT of research on how to build a 16v for boost..And I know everyone puts  down CIS because you can't tune it easily...but with the right parts(mostly volvo 240 turbo parts)you can get a CIS turbo'd 16v to scream...

Anyway thats my 4 cents I guess...and just so you know I am not some ID10T(idiot)I was an auto mech for 20 years and have worked on just about evey make and model of car you can think of...with the exception of say a ferarri or bently(well I did do the brakes on one once)...

Thanks. And im not sure but from ehat ive heard the later 9a internals are forged and have oil squirters. My motor is a 92. And im not sure how the 1.8 16v head flows any better... any conclusions as to how this is?

[A2GTUS]

From what I understand the 1.8 16v head flows better because it doesn't have to hang a hard right turn on the intake side where as the 2.0 16v does look on whoretex..ther e is a lot of info on it there...as far as the forged bottom end of a late 9a you may be right but you will still need to get lower compression pistons to get to the 8.5 to 1 you want for boost...thats the reason the 9a is such a good NA engine because the 10.3 to 1 compression ratio gives it a 134hp ratting...

Good Luck with it and if I can help in anyway just let me know...

[rockinveedubs]

Thanks. I appreciate that. But a new idea has come to mind... my 84 4dr was fun to just cruise around with the 1.8 JH... i figure i can put the car back together with another motor, freshen the suspension and brakes up and have my first car back as my daily... but i still want a 16v. I have another 16v in line for it with less than 32,xxx miles on it out of an 87 gti. All my plans for the 4dr are being put on hold i think till i can build my 2.0 16v and do more research on what fuel management system to use... and id like a 2 dr for all the goodies.
Soooooo...
New plan is do a 1.8 16v swap with my CIS basic or the fuel management the motor is coming with
Raceland header
Rebuild brakes
Rebuild suspension with my sportline springs i have sitting around
Clean some stuff up and respawn my 1st car and my daily driver


Im haveing trouble remembering what the fuel management system used in 87 was... should i use it?

[0dd_j0b]

I have a brand new still in the box set of zimmermann 9.4" drilled rotors and pads. If you are interested.

[rockinveedubs]

I have a brand new still in the box set of zimmermann 9.4" drilled rotors and pads. If you are interested.

PM sent.

Is the 87 1.8 16v ran by CIS E in the GTI golfs?

[Smokestack]

All 1.8 16v engines were CIS-e and all 2.0 16v engines were CIS Motronic. Only the ABF sold in Europe had a multipoint EFI system. I think CIS-e is a decent system, but can get finicky. CIS-m is pure and utter shit. Both the 1.8 and 2.0 had forged internals with oil squirters. The 1.8 and 2.0 heads started out with the same casting. The differences are in the valve sizes with the 1.8 getting larger intake valves, but smaller exhaust valves. Only reason to put out the effort to get one is if you're going for NA only power. It doesn't matter much in boosted applications, unless you're just going for ubber horsepower freak status. To lower the compression on a 16v get some head studs and either double stack head gaskets or get a head spacer. There are plenty of cars out there in the 200-400hp range that do this, and plenty of name brand turbo kits for VW engines that use head spacers. Only time anyone ever has an issue is from their own stupidity with not being able to use a torque wrench. Anything above 350hp and I'd say replace the rods with some H-beams, and you may as well do pistons at the same time. You can cryo treat the crank if you want, but you'll probably snap the block at the intermediate shaft from high HP before the crank goes.

Doing Megasquirt on  the old 16v engines is a bit more involved than just buying the $150 MS1 kit. You need to build a wiring harness and create from scratch a new fuel system for the car with custom components (only component you can reuse is the fuelpump. everything else including the where the injectors go into the manifold has to be replaced). 3/4s of the money I spent on the MS2 setup on my old 16v was on the fuel system. Trying to save a buck with ebay stuff will just send your car up in flames. If you're patient you can sometimes find some good parts off of the classifieds on Vortex that someone just wants to unload.

To run an 02a in a mk1 you either need to do what rotundapig did in his GTI and run the clutch mechanizim on the transmission from a eurovan (02a transmission that used a clutch cable) and a CRX clutch cable (eurovan one is too long and has the wrong end for the pedal. Oddly enough a honda one works), or get really good at metal fabrication. You'll need it because you'll have to build a hodgepodge system from both the B3 and A1 pedals and MC system along with hand built metal bracketry. You'll still need to buy custom mounts or fabricate new ones to mount the transmission.

[0dd_j0b]

or get really good at metal fabrication. You'll need it because you'll have to build a hodgepodge system from both the B3 and A1 pedals and MC system along with hand built metal bracketry. You'll still need to buy custom mounts or fabricate new ones to mount the transmission.

If you want to go this route I can help you out with the fabrication of bracketry and mounts. Just need dimensions.

[rockinveedubs]

or get really good at metal fabrication. You'll need it because you'll have to build a hodgepodge system from both the B3 and A1 pedals and MC system along with hand built metal bracketry. You'll still need to buy custom mounts or fabricate new ones to mount the transmission.

If you want to go this route I can help you out with the fabrication of bracketry and mounts. Just need dimensions.

that would be great thanks. and as far as my motor build and swap goes i have 2 16vs. one is a 1.8 16v and the other is a 2.0 9a. my 4 dr is going to recieve the 1.8 16v because itll be my daily driver. the 2.0 9a im building to boost one day but ive decided that my daily 4 dr will have plenty of power for what its going to be... a daily driver. im looking for a 2 door GTI for a resonable price that i can build up and actually make a beast. The o2a, 9a, and my sciraccio discs are going to go into the 2 door... when i have the money and can find a fair deal. i know that there is a 2 door shell that somone in the club is selling but i need a title. right now im just trying to find out if i should use the stock CIS basic and just run the car with my knock ignition ive pieced together and my sciracco intake or use the CIS- e that i have for the 1.8... ive been leaning toward the cis basic because my car already has it set up and all i need to do is the small amount of wiring and drop the motor in.

Any thoughts? Im open to ideas. Remember... this is going to be my daily... just freshened up with new brakes, suspension and a low mile 16v

[rockinveedubs]

Ive been busy making money and then spending it on new toys so ive neglected the 4dr...
I have a parts car ive set up to buy but the guy always seems to busy so its hard to say when I'll get it. Has blue interior with straght body panels so im gonna strip it and straighten my damage from my minor wreck last year. I was planning on restoring the interior with the original burgundy but i found a set of blue Helios power Recaros so i think im going to utilize the blue carpet and andterior pieces and have Helios interior.

Here is a pic of the front seats. I also have the rear seats. 

[719MKV]

Just turbo an ABA head on a JH bottom end, you'll have fun!

[rockinveedubs]

Haha maybe...  im probably trading my bug for a mk1 vert and putting my 16 v in it and the 8v in the vert will go in the 4dr.

[rockinveedubs]

Anyone know if a cabby rear seat will fit in a 4dr? Found a blue helios cabby rear seat but i dont know if itll fit. I imagine it would.   

[0dd_j0b]

Anyone know if a cabby rear seat will fit in a 4dr? Found a blue helios cabby rear seat but i dont know if itll fit. I imagine it would.

I believe it will. MkI lego's.

[snoopy]

If you need a motor, let me know.  I've got a 9a that I won't be using.