Toyotec's How to install an ABF engine in your Mk2 Golf. Revisit of KJet car 180610

Discussion in '16-valve' started by Toyotec, Jul 4, 2007.

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  1. Toyotec

    Toyotec CGTI Committee - Happy helper at large Admin

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    There are many of you here on this forum who have been asking this question.
    As our Golfs become older we seem to want to keep them very alive to keep up with all the newer "hot hatches". One cost effective way is to install a larger or more powerful motor.
    One of the growing trends is to take a Mk3 1H chassis 16v engine, coded the ABF, and install for more power.
    I will attempt to take you though the stages of one of these installs to help anyone who may consider this option.

    Now the car used for this is a G plate 1.8 16v that came in after the owner had taken a corner on almost 2 wheels and did not remember he had a low oil level.
    [​IMG]

    This method of scattering your conrod shells is not recommended!

    By using a K jet 16v car it was decided to retain all the exsiting systems and use ABF head and block alone.

    Later I will show how this compares with a Digi 3.2 ABF and KR motor and and ABF on Megasquirt.

    Engine installed was a 1995 head and block from Mk3 1H 16v (ABF)

    Aims: To rectify damaged KR unit in car
    To keep the installation as STD looking as possible.
    To utilise the increased torque from using a larger displacement engine.
    To maximise the cost/BHP from such an exercise.
    To test and compare in car acceleration results

    I have attempted to map out my thought process using the table below as how I came about using the ABF head block to achieve the aims vs other VW engines that were available.

    [​IMG]


    Procedure.

    Remove the KR engine and gearbox complete by disconnecting, cooling system, slam panel, intake supply piping, the engine WUR/injector lines from metering head, electrical wiring, exhaust downpipe. CV heat shield and inner CV joints.

    With the engine and gearbox out of the car inspect the steering rack universal joint and boot, steering rack gaiters, CV gaiters or CV joints shifter linkage and exhaust down pipe as this is a good time to carry out rectification work.
    [​IMG]

    On ABF engine remove all Digifant related components including inlet manifold effectively leaving a head and block. Replace cambelt and as an option the water pump.
    [​IMG]

    On KR engine remove complete intake/fuel system as a complete unit by disconnecting the 8, 6mm allen bolts, two 5mm allen from WUR and inlet support brackets from exhaust side of head.
    Remove coolant lines complete including metal line.
    [​IMG]

    Remove radiator top water outlet on head. (has the correct angle for KR inlet manifold)
    Remove oil cooler but not oil cooler housing.
    Remove oil switches
    Remove distributor and leads
    Remove alternator and brackets
    A/C bracket if fitted.
    Remove P/S pump and brackets if fitted.
    Remove 3 one pin temp sensors at the rear of head
    [​IMG]
    Remove thermo time switch.
    Remove MFA oil temp sender near No 4 cylinder under dizzy.

    Remove pressure plate and if in good condition and retrofit on ABF unit with flywheel and clutch.

    On ABF remove 5mm Allen blank for oil temp sensor
    [​IMG]
    ABF remove blank for thermo time switch
    [​IMG]
    ABF remove 2 pin CLT sensor.
    Remove top radiator water outlet (plastic one)

    Give all the components to be used a good clean
    [​IMG]
    These are the cleaned parts
    [​IMG]
    [​IMG]

    Retro fit to ABF head and block all parts removed from KR.

    Coolant system and alternator.
    [​IMG]

    Injection system with new gaskets

    [​IMG]
    [​IMG]


    Attach engine to 020 gearbox.
    [​IMG]


    Take time to address any exhuast manifold issues such as broken studs and cracks.
    On this car the ABF manifold was damaged so the KR unit was reused.


    Finish any works in the engine bay like a steering boot, detailing, tidying loom or exhaust wraping
    [​IMG]

    Reinstall into the car fill with relevant fluids and start.

    [​IMG]
    [​IMG]

    Test and make adjustments. Then get ready to return to owner.
    [​IMG]

    Job done

    Results.

    Straight line comparison for G8** ***
    Notes
    STD car with Montral 1 wheels and ride height and full interior.
    STD 16v modified airbox with oiled K and N panel.
    CIS system on both.
    2Y gearbox on both
    1 in stainless steel system after downpipe with no intermediate box.

    [​IMG]
    The guide was also done overhere with more pictures
    I hope this helps
    Kind regards

    Toyotec
     
    Last edited: Jun 19, 2010
  2. ThE_gOg Forum Member

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    top guide mate:)

    very interesting read

    TG
     
  3. Toyotec

    Toyotec CGTI Committee - Happy helper at large Admin

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    We may need to get this as a sticky. I will add more on this later.
     
  4. Matt G Forum Member

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    i take it you dont sleep much?!!!
     
  5. Toyotec

    Toyotec CGTI Committee - Happy helper at large Admin

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    Sleep time with me is like the variable speed limit on the M25.
     
  6. Antichav Forum Member

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    even though this is of no use to me whatsoever, I salute you sir..

    can we have a 'supercharge your abf' guide please ;) with tips from N7NDO!
     
    Coakers likes this.
  7. Toyotec

    Toyotec CGTI Committee - Happy helper at large Admin

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    Thats on the drawing board along with how to turbocharge your ABF motor.[:D]
     
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  8. Antichav Forum Member

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    Well, then I suggest you get your pencil out!
    You can use mine as a donor car if you like ;)
     
  9. Matt82

    Matt82 Forum Addict

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    that is amazing. how close was it to your 8 hour time estimate?
     
  10. A.N. Other Banned after significant club disruption Dec 5th 2

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    Top contribution [:D] We can leave it as a sticky or move it to FAQ. Will leave as sticky for now in case it messes up editing rights whilst we're all chatting about it.

    Any tweaks done to the metering head to fuel the extra ccs?
     
  11. Leon R Forum Member

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    Thanks for the great post! I've been gathering the info from the sticky's here but how did you sort out the issue of the throttle cable?
     
  12. Toyotec

    Toyotec CGTI Committee - Happy helper at large Admin

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    All I did was to adjust the flap pivot with 5mm allen driver and thats it.
     
  13. Toyotec

    Toyotec CGTI Committee - Happy helper at large Admin

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    Throttle cable? There was no issue...
     
    Last edited: Jul 5, 2007
  14. Toyotec

    Toyotec CGTI Committee - Happy helper at large Admin

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    The car took 3 days to complete on evenings after work. So a spent in all 16 hours to complete whole car. Engine took 2 hours to remove and strip, 4 hours to clean amd retro fit parts and 3 hours to reinstall and get running right. So I took 9 hours.
     
  15. dubDREAD

    dubDREAD Forum Member

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    nice one :clap: wish i had read this months ago [:$]

    cant wait for the supercharged version [:D]
     
  16. TrackCab16v Forum Member

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    great wright up :clap: . did you find any clearence issues with the exhaust, as the block is 16mm taller ;
     
  17. madmk4 Forum Member

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    How were the performance figures measured ?

    Also, do you see any benefit going from the recomended 2% CO to 3 ?

    Mart :)
     
    Last edited: Jul 13, 2007
  18. Toyotec

    Toyotec CGTI Committee - Happy helper at large Admin

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    Mart,
    I used a Gtech-Pro accelometer to measure the car in a straight line.
    Tests were done on the same car, 5 times, in the same location and by the same driver.
    %CO was done at the MOT centre and were based on the best idle speed idle without compromising the MOT limit of 3.5% for older cars.
     
  19. Toyotec

    Toyotec CGTI Committee - Happy helper at large Admin

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    No problem on a MK2 if using either factory 16v or 8V downpipe.
     
  20. madmk4 Forum Member

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    Aha righty oh...The 0-60 time was a little optamistic i thought but consindering my little burn up with an evo 4 several times, that was dead even, could well be correct...

    Evo driver said it was running a BAR boost, does this give much improvement ?
    His excuse for not pulling away was its still got a CAT haha


    For best results of them acceleration data loggers the box needs ot be placed as close to the CofG as possible :)
    Mart
     
    Last edited: Jul 13, 2007

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