2Litre 16v Block Cutaway Pictures.

Discussion in '16-valve' started by Brian.G, Jun 19, 2009.

  1. Brian.G

    Brian.G Forum Member

    Joined:
    Feb 3, 2008
    Likes Received:
    446
    Location:
    West of Ireland
    Done for the future reference of all engine gurus worldwide.
    Should answer all questions in respect to how far out the 2.0l block can be taken to.

    Here we go now, enjoy!

    Engine code 6A.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Green surfaces are VW factory faces, red surfaces are my own cut surface ground faces.
    And the all important measurements>
    Bore 82.50mm
    Stroke 92.80mm
    Average wall thickness of block through out(non high load areas)> 6.00mm.
    Distance between bores taken with a high quality vernier callipers> 5.72mm.
    Average main oil way gallery's diameter> 12.30mm.
    Oil feed to head, average diameter> 5.60mm.
    Distance from bore wall to root of oil squirter thread> 3.20mm. (''root measurement'' as in root of the thread of banjo bolt that holds squirter in place)
    Minimum bore wall thickness> 4.44mm, max 7.80mm.
    Average deck thickness, pretty uniform throughout>minimum measurement> 16.00mm
    Bridge piece across water passage at number 1 and 4 cylinder> 10mm high x 17mm wide.
    Block featured is a standard bore 2.0L 16v 6A external water pump forged crank(this had one?) type block with approx 150k miles.
    I hope these pictures and specs help everyone who is thinking of or in the process of building a great engine.
    I also hope these pictures will put peoples minds at ease with any doubts they may be having when it comes to boring these babies out or planing the deck, tapping oilways for remote supplies, dry sumping,etc.

    Points to note are>
    The bridge across water passage which is not in the 1.8T block as seen in the 1.8T section.
    The mould bridge stabiliser seen between the 2 cylinders, fitted at time of casting to aid stability to cores im sure.
    The general beefiness of the entire block compared to the AUG 1.8T.
    Casting is solid between main bearing carrier and base of bore.
    I stand by all of the above measurements.
     
    Last edited: Jun 20, 2009
    Nige likes this.
  2. A.N. Other Banned after significant club disruption Dec 5th 2

    Joined:
    Oct 23, 2003
    Likes Received:
    395
    Thannks Brian, cracking information once again.
     
  3. drunkenalan Paid Member Paid Member

    Joined:
    Jun 11, 2004
    Likes Received:
    28
    Location:
    Leicester
    great work, well done! and thanks for sharing
     
  4. neil kaye Forum Junkie

    Joined:
    Feb 13, 2008
    Likes Received:
    13
    Location:
    england
    thing you have a secret fetish between engines and angle grinders brian :lol:
    great work mate ,is this what your going to do with the 1.8T in the 20v section too
     
  5. Brian.G

    Brian.G Forum Member

    Joined:
    Feb 3, 2008
    Likes Received:
    446
    Location:
    West of Ireland
    I may have, dont tell anyone though :lol:
    the 1.8t is the first one i did and up in the 1.8t section, where have you been:lol:
    16v head pictures up by lunchtime tomorrow, just setting them up and finishing the painting, this one is very colour by numbers[:$] :lol:
     
  6. neil kaye Forum Junkie

    Joined:
    Feb 13, 2008
    Likes Received:
    13
    Location:
    england
    yea sorry didnt see it there in the sticky section,would love to see this done to a KR or is the 6a identical
     
    Last edited: Jun 20, 2009
  7. Brian.G

    Brian.G Forum Member

    Joined:
    Feb 3, 2008
    Likes Received:
    446
    Location:
    West of Ireland
    Im doing it on a 6a which as Toyotec pointed out in the 16v audi 305 hp thread has the same p/n as the abf casting.
     
  8. Brian.G

    Brian.G Forum Member

    Joined:
    Feb 3, 2008
    Likes Received:
    446
    Location:
    West of Ireland
    Just to give you an idea of what the core ties or ''chaplets'' look like before water jacket core is installed, this picture is of a 6 cylinder something but the principal is the same.
    The sand is mixed with 7% sodium silicate which in the presence of co2 gas causes the core to set hard and keep its shape during the pouring process. Notice how the core is sprayed with a gas proof wash, this prevents hot gasess emitting from the core and ruining the block casting, instead, the parts which become the frost plug holes are left un-treated and the hot gas inside the core flows through the sand and out these porous areas instead, the sand core is then washed out of the finished block by dipping it in solvent which breaks down the bonds between sand particles, clever stuff;)
    If only they used a slighty thinner waterway core in the 16v block, it would cut down on flex a good bit when bored out.....hmmmm
    [​IMG]
     
  9. Nige

    Nige Paid Member Paid Member

    Joined:
    Dec 12, 2006
    Likes Received:
    2,134
    Great post. Must have taken a lot of time and effort, so thanks for doing it and sharing the info.
     
  10. Brian.G

    Brian.G Forum Member

    Joined:
    Feb 3, 2008
    Likes Received:
    446
    Location:
    West of Ireland
    You are very welcome Nige,

    Brian,
     
  11. RobT

    RobT Forum Junkie

    Joined:
    Oct 24, 2003
    Likes Received:
    948
    Location:
    Cheshire
    very good to see you back Brian
     
  12. RisQ New Member

    Joined:
    Mar 18, 2013
    Likes Received:
    0
    Nice. Great help.
     
  13. Brian.G

    Brian.G Forum Member

    Joined:
    Feb 3, 2008
    Likes Received:
    446
    Location:
    West of Ireland
    Thanks Rob,
     
  14. thegave Forum Member

    Joined:
    Nov 4, 2008
    Likes Received:
    2
    Location:
    London
    I hope you stay around BG
     
  15. Brian.G

    Brian.G Forum Member

    Joined:
    Feb 3, 2008
    Likes Received:
    446
    Location:
    West of Ireland
    Intend to, learned a lot more the past two yrs re heads, you gotta know about it. Soon,

    Brian,
     
  16. thegave Forum Member

    Joined:
    Nov 4, 2008
    Likes Received:
    2
    Location:
    London
    Has the BG head been cast? Need pictures!
     
  17. Brian.G

    Brian.G Forum Member

    Joined:
    Feb 3, 2008
    Likes Received:
    446
    Location:
    West of Ireland
    Not yet, but nearly there now. My fumbling around with heads got replaced with fumbling about in Hong Kong for a while.
     
  18. RobT

    RobT Forum Junkie

    Joined:
    Oct 24, 2003
    Likes Received:
    948
    Location:
    Cheshire
    Very interested in this idea. Looking forward to discussion....
     
  19. Admin Guest

    Pictures and a detailed report please ;)
     
  20. Brian.G

    Brian.G Forum Member

    Joined:
    Feb 3, 2008
    Likes Received:
    446
    Location:
    West of Ireland
    Not much I can say really, its a FINE place with a lot of factories nearby. The detailed report consists of a patent now assigned to the client, with a large nda so ''nothing to see here'' lol.
    Do you really want to see pictures of HK?

    Brian,
     

Share This Page

  1. This site uses cookies to help personalise content, tailor your experience and to keep you logged in if you register.
    By continuing to use this site, you are consenting to our use of cookies.
    Dismiss Notice