Mk1 76 2L "ABAout time" swap

[Antonvs]

About a year after purchasing my first mk1 golf I realised that the engine just was losing power at about 5000 revs. My car could no longer hold compression due to worn piston rings and was breathing heavily and blowing more oil out the top than the BP oil spill. Drastic action was neccesary!
My realistic options were,
1.8 Engine swap,
original 1.6 rebuild,
original 1.8 bore and rebuild
2.0 ABA rebuild and engine swap.

I went for the ABA! This is my rebuild thread, I wish i took more pictures but this is what there is!

I cant load everything at once but will over the next few days.

Many Thanks also to Roccodingo for helping the rebuild along with much time,advice and parts!!!

After thoroughly robowashing the block and the head, along with getting both skimmed and the whole engine and flywheel balanced we set about assembling the bottom end.



skimmed head with new valve guides and seals, Valve seats ground.






Patiently waiting for new engine!


---------- Post added at 11:21 PM ---------- Previous post was at 11:17 PM ----------

Couldnt resist to post the final product! More photos of engine build to come.....

[HaydEn]

Wow.

This is beautiful, good work sir.

I like your title too

[Gipson]

looks great Anton.
glad to see it's all worked out you guys put some quality work into it!
you'll have to show me the finished product in the flesh soon

[roccodingo]

Ha !! Anton, you make is sound like a quick job ..

We worked out the priority was to make the car a reliable vehicle, able to do daily driving duty if required.

Plannining = 2 + Months
Collecting parts, waiting for mailman = prob 6 + months
Waiting for me = 4+ months...lol

There was a ton more work involved which required pretty well a complete rewire of the car + several fuel tank swaps, fuel pumps etc.

Maybe we should upload the list !!!

Good work mate and glad to see your finally enjoying the benefit of all that effort.

[Antonvs]

Ha ha yes there certainly was a lot of work into it. A solid 6-7 months of weekends! I will be uploading more of the job when time allows!

[BonsaiTiger]

Woooaaah that is a pearler. Looks the business man!

[Volksee77]

Great job too guys, I was lucky enough to go for a quick spin around the block in it and wow it pulls hard and the exhaust system sounds sweet. Very nice, tidy and quick mk1. Definitely was worht all the effort you guys put into her

[roccodingo]

Engine bay pic after the new lump was fitted. Re-positioned airflow metering head box. Factory colour coded wiring about to commence.



Engine sat low enough not to cause any problems with the bonnet closure. ( 2E long block ) though the throttle body is close to the bulkhead raintray.

[Antonvs]

Thanks For the comments Luke, Dubdan, Bonsai Tiger and Hayden, yeah it sure has paid off all the hard work we have done to it.
Photothread continues,
New bearings, made sure we checked the clearances with plastic guage, which helped us pick up an out of round conrod. We luckily had a spare set of rods which we were able to change over! The second set were all within tolerance!

arp rod bolts

Windage tray

I reccommend using this piston ring compressor as we had some mishaps with the tapered sleeve arrangment!


Before

After

Sump on


---------- Post added at 10:41 PM ---------- Previous post was at 10:37 PM ----------

A comprehensive parts list! just to give you an idea! I have part numbers or info where to get most of the stuff if anyone needs it.
Parts
Engine block
Engine head
New fuel injector lines + fuel lines and connectors
CIS seal kit
New fuel injectors
freight
Rear axle beam pivot brackets (epoxied)
K jet injection bolts
Rocker cover
Fuel filter x2
Oil filter x2
Oil change x 2
radiator coolant vw stuff x 1
Fuelpump x1
Electrical relays
Electrical harness (heat shrink, crimps, etc Lots of work!!)
Front grille
Plastic rear light covers (inside boot)
Distrubutor
Distributor electrical unit
Injector housings plastic
Spark plugs
Brake fluid
Large Throttle body
Accelerator cable
Alternator
Warm up regulator
cv boot cover 90mm x 1
cv grease
Welded up air intake manifold
Fuel tank x2
Water pump pulley
Spark plug coil
Water heater steel pipe
Gearshift bush kit
Elbows and pipe for exhaust reroute
Misc plated bolts
Misc consumables
Fuel sender unit
Fuel pump bracket
Fuel pump insulator
Accumulator bracket
Alternator bracket
Distrubutor re curve
Bushing Intermediate shaft F&R
Rod bolt set
Con rod nuts
Gasket set ABA
Bolt crankshaft sprocket
dipstick holder
Dipstick
Headgasket
Gasket set update kit
oil seal
Exhaust manifold gasket
Gasket intake manifold
Seal valve stem
Windage tray with gasket
Ring set 82.5mm
timing belt
timing belt tensioner
stud kit, tensioner
main bearing set w/o thrust bearing
thrust washer set
Oil filter flange
rod bearing set
Freight
Hose pump to head
hose pump to head w/o a/c
hose clamp
hose flange to valve
hose clamp
hose clamp
heater hose feed and return
hose oil cooler upper
hose pump to oil cooler pump
hose clamp
hose pump to pipe
upper rad to head
hose rad lower
baffle oil pump pick up 14.95
Freight
top plastic cam cover
lower plastic crank cover
Alternator backets
Exhaust 4-2-1
gst
Genie exhaust system
engine cover bracket
cv boot inner x 2
cv boot outer x 2
Fuel pump bosch
fuel sender o ring
freight
Barrys engine tune up
tt hydraulic camshaft 268deg
distrubutor aba kit
block off plate engine breather
freight
engine oil pan
valve cover oil deflector
radiator fan switch
thermostat 71C
freeze plugs
freight
face head
supply and fit inlet guides
supply and fit exhaust guides
acid bath block
face block
full engine balance
cut seats and face valves
hex nut john hughes
oil tem sender
brake light switch
clear indicator LED
cross hair clear headlamps
freight
new battery
Wheel bolts and spacers
fuel injection fusebox new

[Jarred]

looks great, really good with the wheels.

Congrats on the engine swap

[GoLfMan]

that looks awesome mate! Looking forward to more photos!

[Bflat]

Nice wheels

[Antonvs]

Water pump on and oil cooler about to go on.

Had to swap from my air to oil cooler to water to oil cooler unfortunately!



This is just an empty head! Hydraulic lifter and cam to go in. new rocker cover gasket.

268 techtonics/vw motorsport cam progress! lifters in, after being soaked in oil for a week trying to get as much oil into the small dia galleries! cam about to be bolted in.



Tensioner and cambelt on.


---------- Post added at 09:41 PM ---------- Previous post was at 09:39 PM ----------

Nice wheels

Thanks and likewise are they phase twos on your polo? the Ronal writing is a bit smaller...

---------- Post added at 10:24 PM ---------- Previous post was at 09:41 PM ----------

And the engine looking schweet!


Video of old engine while it was still running! apologies for 90rotate dont know how to fix on photobucket.... yet.

http://s782.photobucket.com/albums/yy103/antonvs1/Engine%20rebuild/?action=view&current=Mk1Golfoldengine1600.mp4

Next step to get the old engine out, so first thing is to get the old engine and bay nice and clean.
this helps:

After i washed it, the old engine decided to no longer want to start and truly decided that it no longer wanted to live!
hence a tow was required to the chop shop! it ried the whole wd40 distributor routine but no dice!
In the chop shop!


Just a nice photo of rear stance in Perth CBD I thought fellow dubbers would enjoy.