White VW Mk2 w/ 2.0L ABA + Digi2 8v

[SlimMJS]

A Brief Summary:

--Starting with a 1992 Alpine White 1.8L 8v with 212,000 miles

--A 2nd lower mileage 8v head and have rebuilt. everything done short of port and polish. INCLUDING 268º CAM.

--An 2.0L ABA engine from the junkyard, estimated at 90,000 miles, compression was good. decent shape overall.

--The DigiFant-2 ECU wil be maintained with the original electronics of the car

--The original 020 Transmission will be kept. Expecting a flush and fill with Red Line fluid.

--Air Conditioning removed.

--Alternator from a Mk3 (90 AMP)

--Original Power Steering Pump and Rack kept.

--75% of the V-Belts were eliminated, mostly Serpentine now.

--New Injectors, Plugs, Drive Axels,

--Sachs Clutch with Re-Surfaced Flywheel.

--All new gaskets and seals wherever possible.

--Many parts cleaned and/or painted.








IT HAS BEGUN


Here\'s the 2.0L ABA stripped
http://farm3.static.flickr.com/2409/2276626487_ac44d1c814_b.jpg

And all the parts I took off of it
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All photos can be found HERE (http://www.flickr.com/photos/matthewslimmer/sets/72157603946691786/)

[teddymac]

SlimMJS wrote:

IT HAS BEGUN



MORTAL KOMBAT!!!!!!

cool mk2 (pic\'s on your site)!

[SlimMJS]

Day 1

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[audivwdave]

WE DONT HAVE ANY ENGINES !!!

[Digital K]

im hot. :ohmy: :dry:

[teddymac]

someone took my beaniebaby under the bumper idea

http://matthewslimmer.com//engineswap/Day1-Highlights/images/img_8463.jpg

what animal did you use glen?

[Tj Hunter]

I like that I am thinking i may do it too.

[SlimMJS]

Day 2 was less eventful.

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[Digital K]

taking the bell housing on and off 3 times is laaame :P:laugh: :laugh:

[SlimMJS]

taking the bell housing on and off 3 times is laaame

Nah, it was like Karate Kid.... \"Bell Housing On, Bell Housing Off, Bell Housing On, Bell Housing Off... Gooooood\"

:silly:

[Digital K]

I am pooping in this picture, just to premptively answer any questions...

http://matthewslimmer.forsmanphoto.com/engineswap/Day2-Highlights/images/img_9127.jpg

[SlimMJS]

We need this tomorrow! anyone???

For the Water pump and Power steering pulleys...
http://www.parts4vws.com/images/parts/T.96280.jpg

[OptimusGlen]

sorry I couldn\'t make it out tonight, I\'ve been really burnt out the last few days.

[SlimMJS]

Day 3, engine is in the car (minus the head)

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[Digital K]

we do fractions here... and covert mooning. B)

[Broseph]

OptimusGlen wrote:

sorry I couldn\'t make it out tonight, I\'ve been really burnt out the last few days.

HAHAHAHA GLENS A BURN OUT!!!!! i knew it

[SlimMJS]

Day 4. Engine is totall IN and we tried starting. No luck. Yet.

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[Broseph]

kris, your like a 6 year old that doesnt get your candy when you get frustrated, its really cute....er.....ah........fuc..........., looking good

[Die Frau]

Damn, look how clean that one bracket is...

Sorry I wasn\'t more help to you guys, but call me again if you need any cleaning...

So what is the latest news?

[SlimMJS]

Day 5. Completely RE-Assembled. Still no start. Played with Timing, Plugs, Wires, Dirtributor, etc. Gonna let Chad at SCI take it from here! :D

[SlimMJS]

Current Status/Issue:

Tried starting the first time with new 1.8L 8v Bosch Super spark plugs. OEM splug wires (not as old as 212,000 miles, but not brand new), the Distributor which was was kept on the ABA block from when we got it from the junkjard (with a new Cap).

The engine cranks hard and kinda sorta barely sounds like it would start, but basically, it\'s cranking pretty smooth.

Kris is a timing master on these, so we KNOW it has timing RIGHT ON. He triple checked it.

Brent tried re-arranging the plug wires on the Dist Cap to the order that we think the ABA is used to firing to match the order that the 1.8L head is used to. (if that makes any sense).

Either way, it only fires every once in a while.

The plugs are getting spark. I think all of them, but we didnt try ALL, I don\'t think.

---------------

The distrubtors are visually different, so I think that the suggestion by more than 3 people about switching the distributors will work.

Tomorrow I switch the Distributors, Caps, Rotor, Plugs and Wires to all 1.8 stuff and see what happens!

[Digital K]

dizzy before chad B)

[John2.0T]

The documentation with all the pics is awesome!!! Its really great to follow the whole procedure...

[SlimMJS]

IT\'S ALIVE... ALIIIIVE!!!

[Tj Hunter]

NICE!!! Congrats. Can not wait to see it again.

[SlimMJS]

AS of yesterday, she became road-worthy. I drove it over to SCI to be tuned. One snafu along the way, but she made it. It sounds pretty nice. Very different than it did, for sure. Lower and lumpy and louder. It wasn\'t producing much of any power yet. Perhaps the timing is off a little. Perhaps I didnt get that distributor in there juuuust right. I dunno. The Pros over at SCI will know :)

[flippinvw]

Hope Chad can get it worked out Matthew!! B)

[SlimMJS]

He already did!

...at last! she\'s all done. and VERY road worthy. it\'s a blast to drive again! weeeeeeeeeeeeeeeee!

[SlimMJS]

why have I NOT kept up with my car build thread!??!!? I'm going to refresh the photos and see what else I can add since friggin september 06. geez. what a chump.

[CaRJoE0220]

anyone else not know what the hell is going on? None of these pictures work for me and people are talking about pooping and asses again

[CaRJoE0220]

oh i see, ill wait

[SlimMJS]

oh i see, ill wait

atta boy. no words, just looking for purdy pictures :bangin:

tonight I'm going to refresh all the photos and fill y'all in on all the junk I did since 9/06. I'm just mad at myself for not keeping up with this thread!!!

[Hart]

why have I NOT kept up with my car build thread!??!!?You've been too busy pounding some metal thing into place with an assembly of socket extensions though the grill

[SlimMJS]

all old photos have been re-linked. tomorrow I'll take some pics of newer mods that I've missed along the way.

[vweezly]

How the eff did I not see this. Fantastic photos and documentation. That's one clean build Matthew and friends. Why don't you pussies work out in the -10 degree weather like the rest of us :D (I jest... I am jealous .)

[SlimMJS]

How the eff did I not see this.

Joel, these are from my swap back in Sept 06, but I forgot the thread and never updated anything as I continued modding my car. It's taking me a little while to get it current, but it shall be. More pics tomorrow I think.

[vweezly]

Joel, these are from my swap back in Sept 06, but I forgot the thread and never updated anything as I continued modding my car. It's taking me a little while to get it current, but it shall be. More pics tomorrow I think.

Rad.... glad I'm not loosing it haha :biggrin: I look forward to photographs :beer:

[SlimMJS]

1/9/07: Cabrio Triple Gauge into Center Console
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Summer 07: SCI Heavy Duty Spark Plug Wires
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Summer 07: Neuspeed Front Strut Bar (painted to match)
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7/2/07: GLI Recaro Front Seats
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7/12/07: Magna-Flow Resonator and Muffler
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7/17/07: BBS RZ (Corrago g60) Wheels with Yokohama AVS ES100 Summer Tires
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10/30/07: KPH Speedometer Cluster with Custom Red Painted Needles to Match
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11/22/07: Houndstooth Headliner
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1/20/08: Rabbit Radiator w/ Built-in Expansion Tank (death-star removal)
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1/22/08: Corrado 11" Rotors, Spindles, Carriers & Calipers (was 9.4")
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1/28/08: Techtonics 2" Race Downpipe (Non-Cat)
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1/28/08: 22mm Master Cylinder (from stock 20mm)
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1/28/08: Stainless Steel Brake Lines
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1/30/08: Techtonics Block-off Plate
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2/15/08: EBC Green Stuff Brake Pads
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[SlimMJS]

there! updated pretty well. :D

[Digital K]

:)

[dubswede]

i thought this had an aba head in it?

i like this thread, such clear, quality photographs.


and this looks perfect.
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[SlimMJS]

Wheels:
so I had my summer tires on 2 weeks ago, then spent two days with summers on the rear and all-seasons on the rear. It was mega japanese and everyone loved it. Back to all summers again now, haha.

New Lip:
the deeper 16v lip installed
http://mt11.quickshareit.com/share/img_03710c0d5.jpg

New Floor Mats:
I had deep rubber mats in for the winter, but I also had thrown out my super old GTI stitched mats since my heel had worn completely through the carpet on the mat and the tough backing. it was pitiful. these are purdy.
http://mt15.quickshareit.com/share/20080414img_03669cf4c.jpg

stuff like floor mats are something that mk4-> drivers take for granted. this was a totally great find. FYI, the part number is: ZVW 17B 829
http://mt11.quickshareit.com/share/20080414img_0358befc8.jpg

[Digital K]

looks like a great fit :)

[hamradio]

After seeing it up close, it is even hotter than the pics!

[SlimMJS]

oh, also claybar-ed the hood with the bar that Pete left for me after he finished Tracy's cabrio. HUGE improvement to the touch and a lot of specks of shit are gone now. I had no idea.

[hamradio]

Was that before or after I saw it? I thought it looked really nice and smooth. The paint isn't original, is it?

When I claybar'd my rabbit, it was so much smoother.

[momo]

thanks for the update! i was looking for the thread for your car the other day. i like those BBS's. If you ever want to paint them i'd suggest white centers. I've always thought white on white looked awesome. but anyways, it's looking great!

[Die Frau]

Sweet, You used the clay! I have given clay to others in the past and they never use it. What a waste. This stuff should be used 1-2 times a year and will amaze you every time!

[hamradio]

After claybar, wash, and wax, my rabbit's old paint was so much smoother. Stuff seemed to reflect in it nicer, too. I need to buy some more sometime soon, I don't know where my chunk o clay went.

[SlimMJS]

Sweet, You used the clay! I have given clay to others in the past and they never use it. What a waste. This stuff should be used 1-2 times a year and will amaze you every time!

Well, I just did the hood to start, and it's great. I hate tree sap.

[SlimMJS]

thanks for the update! i was looking for the thread for your car the other day. i like those BBS's. If you ever want to paint them i'd suggest white centers. I've always thought white on white looked awesome. but anyways, it's looking great!

I will never color match wheels to a car.

[tobin999]

what brand claybar was it that you used?

[palmer]

Very nice!


I kept meaning to ask you about your car...

It looks great!

[Digital K]

I like the new lip :)

[Die Frau]

Clay was from Zainos. Buy it online.

[dubswede]

what condition was your old gl lip in? I'm thinking I might want to revert back to a smaller lip this summer.

I love new floor mats too, and driving barefoot on them.

[aaronmjr]

good read. :beer: very tasteful stuff. I dig the OEM+ theme.

[momo]

I will never color match wheels to a car.you don't like the look? it doesn't matter i guess though, people are entitled to their own opinions.

[SlimMJS]

FINALLY got a matching rear Recaro seat. Installed just before the show. Sorry I didn't update this thread.
http://farm4.static.flickr.com/3037/2594871411_5aa63fa1bb_o.jpg

Moved the 268º cam from the GTI to the SPORTRUCK to install a 272º cam! Thanks for the help Pete!!
http://techtonicstuning.com/images/parts/109.528.jpg

[Digital K]

you better be sorry.

[Die Frau]

Car still running strong?

[SlimMJS]

heck yes!

[aaronmjr]

awesome. the seat looks like it's in great shape. what kinda differences did you notice with the new cam?

[SlimMJS]

there isnt very much difference going from a 268 to a 272. I notice a difference at idle. I havent really wound it out yet though. :)

[hamradio]

Are you still running stock lifters and springs with the 272?

[momo]

nice, any videos? oh, and have you dynoed it lately? iirc you said that your last dyno numbers were just under 100whp without a few mods that you have now(correct me if i'm wrong).

kinda off topic but, that sportruck must be pretty fun to drive with the 268 cam

[Hart]

kinda off topic but, that sportruck must be pretty fun to drive with the 268 cam
It hauls nicely

[SlimMJS]

NOW I can tell a difference that I'm pounding on it a little more. The upper RPMs are stronger and the exhaust sound changed a little. Kris is right though, if you want big power, gotta double them valves, haha. Or force some induction. :D

[momo]

Sorry to bump such an old thread, but what suspension setup are/were you running? I can appreciate the subtle oem+ theme a lot more now, than I used to.

[SlimMJS]

Sorry to bump such an old thread, but what suspension setup are/were you running? I can appreciate the subtle oem+ theme a lot more now, than I used to.

Previous owner installed: Tokiko Springs + Bilstein Shocks. I like the ride.

[momo]

Cool, how does it handle? And it doesn't rub at all right?

[SlimMJS]

Handles good. I've never been angry at the suspension. No rub.

[momo]

Nice, if I pick up a mk2 GLI that I was offered (and I most likely will), I'll keep the tokico springs in mind. I'm looking for a good setup that is mildly lowered, handles good, and doesn't rub. So nothing super slammed. Probably either neuspeed springs, tokico spings, or GC coilovers.