1.8 16v turbo (+ injector questions)

hi all i am/was in the process of building a 2l16vt but have decided
maybe the 1.8 16v might be better for me. The only thing is i have a
couple of questions that need answered if someone could help me please.



1. i have the 1.8 16v engine sitting in my garage doing nothing,now what needs done to this?



2. do i need to change pistons and con rods?



3. i know it will need a new head gasket but is there any other way to
do it rather than stack head gaskets to lower the compression?



4. how do i make the 1.8 into a 1.9?



any help would be gratefully appreciated



thanks ryan

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Edited by: RyanMc547

 

Keep it a 1.8. Use S2 pistons(forged) and rods. And use a G60 head gasket. A c/r of 9.3-1 but the pistons/rods/crank are man enough for 300-350ps/lb ft.


Any more questions?

 

yeah just one if thats ok . why do i have to change the pistons and rods to s2 items?



cheers ryan

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If you dont change the pistons and rods the chances are the standard 16v equipment will melt at high boost.


Most people use Forged Pistons as they are lighter and much stronger.


You can get forged pistons to order. If you do buy them look at the yank websites as they are alot cheaper.


You are looking at around 100 a piston from JE.


Again 16v rods are probably ok but the pins are the weak spot on the standard rods. Im fairly sure you can use the pistons and rods from a G60 as they are built much stronger. and have larger pins.


hope this helps.

 

thanks very much for that druid i will now try and see if i can get g60 rods and pistons



ryan

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i dont think G60 stuff will work. doesnt fit for some reason.

JE pistons are the way to go for good boost. can be had for alot cheaper than 100 quid each. depends how cheap you can get them shipped back to the UK. i got mine sent to a friend in the usa who bought them back over so they where alot cheaper than 400 quid.

it would help if you said what turbo you are planning to use. how you plan to controll the ignition and fuel.

i would say the KR rods are ok for 300bhp, using a smaller T3/T4 garrett turbo. alot of people on VWvortex have proven the rods to be quite strong indeed. if you want to upgade the rods, scat, do some for the 16v motor for 200 - 300 quid a set, again, depends on how cheap you can get them shipped over from the USA.

like u say, going to 1.9 would be a good idea when changing the pistons. so you want to order 83mm ones if you do get some. you might want to invest on ARP head studs and maybe even rod bolts. a metal head gasket will be needed too.

 

i dont think i am going to use g60 stuff now as a friend of mine has
used on his mk1 turbo normal passat petrol engined pistons and it seems
to be working fine. so thats another idea.



im going to use a t3 turbo and then control the whole lot with a
megasquirt management system and also using an audi 1.8t headgasket or
i saw a rather nice copper one on eip tuning.



so how would i go about changing it to a 1.9? is that by using a diesel crank and 83mm pistons?



any help would be gratefully recieved



thanks ryan

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83mm pistons will do the job. no need for a crank change.

you mate with the mk1 turbo, what engine did he get his pistons from? if your going to buy another engine to get pistons out of, you might as well stick a 2.0l 8V tall block in, with the 16v head. get the engine from mk3 golf etc... think its an ABA. then you will have a 2.0l 16v with about 8:1 compression. allthough i think you have to get the pistons groved to clear the extra valves on the 16v head. search for more info on this.

you can pick them engines up pretty damn cheap. better if u find somewhere that will sell you just the bottom end.

 

hi there all i know is my mate said they came from a passat but he bought his brand new and paid about 100.





i was going the 2l 8v route but since i had most things lying about for this conversion i thought i would do it.





so all i need to do is get some 83mm pistons for the increase.i think i will get a set then.





what are you running in your engine?is yours the 2l 16v turbo? what engine management system is yours running on?





cheers ryan

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Also i have a quick question about injectors as well. i was planning in
using g60 ones but have been told that will limit me to about 230brake.
so if i used 1.8t ones what will i be able to achieve with them? or am
i just better using the cosworth ones i have sitting. <!--
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G60 greens are bin fodder on a charged 16v, I`ve got a set of 440cc`s from G-werks and they fuel well at 1bar boost. What management are you running? as most early ford injecotors are low impedence and need inline resistors to bring them up to 14-16ohms for VW`s digi1 (G60) management.

Box and clutch is another problem, I`m running Helix paddel in min and even that won`t take whatever mine throws out at 1bar..

 

im going to run it on a full megasquirt ecu and ignition control
system.So you think that running it on cosworth injectors wont work?
Without going out and spending a fortune is there any other ones you
can recommend.How much can the stock injectors handle? I take it wont
be enough for a turbocharged motor.



cheers ryan

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Cossie injectors will be fine up to a point, all depends on their flow rating as to how much power you can run before they run out of capacity, as with any injector. Have you had a read of the MS manual for tips on injector sizing? Standard cossie injectors can be bought secondhand for peanuts and should be OK for about 250bhp, maybe a wee bit more. As Keith has mentioned they are low impedance, not a problem if you're buying a new Megasquirt as the new v3 boards can cope fine, but for an older v2.2 board i'd recommend getting a flyback board as well.

 

ive gone for the saab injectors the flow rate is pretty good 359cc/pm the G60's are 245cc

the Bosch number is 280150421 and they are from a 2.3 9000 turbo

 

cheers for that i might invest in saab injectors then if they handle it
fine. At this moment in time martyn i have not read the ms manual i
might do that at work tonight.



cheers ryan

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Depends what boost you plan to run 350`s whouldn`t fuel near enough for me (1bar)?

 

Are your injectors the red top #30's on g werks website? Also has
anyone any pics off there engine they can post up so i can have a look
at them. What company did people use for there intercooler pipework etc

What sort of power is peoples cars putting out so i can just get a rough idea of what i may get.



cheers ryan

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Not a turbo, but a few pics of my setup here.

 

So martyn what is it that you have done with your car? Is it mappable
ignition and ecu that you have put on the car? Why have you put the
coil pack on the car have you removed the distributor? Whats the
advantages off doing that?



cheers ryan

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At the moment it's a fairly standard 2.0 16v (9A) running Megasquirt'n'Spark in preparation for fitting the GSXR1000 throttle bodies i've had kicking around in my garage for the last 20 months or so (I work slowly ).

The pic of the coil pack on that page is a bit decieving, it's one more of the many bits I have that haven't actually found their way onto the car yet. Eventually I will get round to getting rid of the distributor, but for now it works alright with MS so i'm in no great hurry.