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Discussion Starter · #1 ·
Assembly has finally begun.
Since my Interior Project is now complete -> http://forums.vwvortex.com/zerothread?id=2772227, I finally had some time to start assembly of my Hybrid 2L-20v G60.
Planning, parts gathering, prototyping and machine work has been going on for about the last 6 months, but Assembly finally started yesterday. And progress has been great with no snags thus far.
Here is the plan for those who don't frequent the G60 Forum:
- 2L ABA Bored to 83mm with Custom JE Forged Pistons (9.25:1)
- ABA OBDI block with Forged Internals, ARP hardware, Resized and Shot peened rods
- AEB 20v Head (Large Port)
- Custom Modified SuperSprint SS Mk2 16v Header re-Flanged for 20V
- Light PnP and gasket matching
- Stage IV G60
, Pulley size TBD to match higer revs
- MsnS-e
- FMIC Precision Core under Dietrich RS
- Euro AGU Intake
- some other stuff
1.) Before I begin, let's get some semantics out of the way. This project is not about "the biggest numbers on the tex" so please don't talk about Big Turbos "BTs" here.
2.) If you have any basic questions on 20v Hybrids, please visit this thread -> http://forums.vwvortex.com/zerothread?id=1674618. Al ot of details on my research and specifics are in there.
3.) Although I am not the first 2020 by far, my setup will definitely be unique and will be full trim with A/C.
3.) pic centric thread as usual.

DisAssembly of donors






Since no machine shop around here had a Torque plate to bore my block with, I decided to make my own




Painted Block


Pinning the Crank Pulley



ABA Intermediate Shaft Modification for distributer using AWP 52T Cam Gear (initially)





Modified by sdezego at 6:24 PM 1-2-2007
 

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Discussion Starter · #2 ·
Re: Project Build: sc2020 (sdezego)





After Checking the IM Shaft bearings, I realized that the machine shop honed them to big... I shoudl have just done them myself to begin with.




Checking the Crank Shaft Axial Play




Plastigage'ing the Mains. I always check..




Modified by sdezego at 6:28 PM 1-2-2007
 

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Discussion Starter · #12 ·
Re: Project Build: sc2020 (Pigsdofly)

Quote, originally posted by Pigsdofly »
Why go through the extra work to fit the dizzy if your using the MSnSe, it's a thing of simplcity to run a missing tooth setup from the get go.

An excellent question really. Especially, since you need to do a special board tweak for MSnS to accommodate VW's Dist Hall Sensor.
The orig plan was to Build MS, Config and install it on my existing G60 on Dist, get it tuned and run it for a while. Basically, get it all ready to throw on the new motor and then have to just tweak the maps rather than work out any bugs on the new motor. Still the plan actually, but since I finished the MS build a few months ago and the motor is well under way, the idea is making less sense.
Also, I already had all of the stuff for ABA Dist and the only thing I needed was the Cam gear and a 20 minute IM Shaft mod.
The past week or so, I have been seriously rethinking this though and may go 60-2 Coil pack right off. I may even setup a 60-2 on my current PG to get it all ready. I go back and forth.



 

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Discussion Starter · #15 ·
Re: Project Build: sc2020 (leebro61)

Quote, originally posted by leebro61 »
Well wait a second, if you bored out a 2.0 block... isn't it a sc2120 or 2021 or 21.xxx

Not all that much gain on a 4 cyl only going .5mm. Stock ABA is 1984cc @ 82.5mm Bore. 83mm Bore brings it up to 2008cc
 

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Discussion Starter · #17 ·
Re: Project Build: sc2020 (UTdaneVW)

Quote, originally posted by UTdaneVW »
Thats going to be such a sick motor. http://****************.com/smile/emthup.gif
I want to see this car in person, all the work on the interior and now this.
Def holding it down for the FL Rado scene.

Thanks! You will definitely see it. Been driving it alot lately and enjoying it. Realistically, the motor will not go in for a few months as I am not rushing it. LOTS of stuff to work out between now and then.
Among other things, I am thinking about the gearbox as well. Peloquin at the bare min, but need to sell some more parts to pay for that. I have also been thinking about an 02M lately
That is just a matter of money, not effort.
Shawn
 

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Discussion Starter · #33 ·
Re: (sdezego)

Been out of town and busy, so no major progress except for spending more money and more circular decisions regarding ignition.
I have some 16V IM Shaft parts coming Tues, so I will make a Final decision on Dist vs Coil Pack (or COP). If you want to know what I think was the final clincher, you may laugh. I will be running the Timing belt guards and the lower AEB guard will not fit on the 52T IM Shaft Gear for Distrubuter (obviously since the AEB uses a 43T gear like the 9a).
It is just one of those things you don't think of until you go to do it. Also, the 43T gear will turn the Oil pump faster, which can't be a bad thing
I just want to take the ABA and 9a oil pumps apart to compare and make sure this is nothing I am missing (other than the forked vs splined shaft). I am almost certain the gears are the same size, but want to verify reliefs and such.

I did get my Vr Lenses and Bezels installed on my ECodes though. All I can say is Flush! The G60 Ecode gaps and steps from Vr grill to fenders really annoyed me. I also have a set of Vr Fogs coming for the RS Front that will house the Precision FMIC.
Mock pic of the head and belt on (now all subject to change). I also, did not make the tensioner mod yet to affix it (since the stock 20v uses the hydro damper and relay roller).






Modified by sdezego at 5:37 PM 1-2-2007
 

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Discussion Starter · #34 ·
Re: (sdezego)

I had a few questions about how I was going to modify the 20v Tensioner, so here is my off the cuff ideas.
1st - If you are not running a Dist and plan on running the 16v/aeb IM shaft 43T gear, then you can simply use the 16v "fixed" type tensioner with the 157T custom belt and call it a day. No need to read on in this post.
If you are running Dist (Which I was going to), you have to run the only available "correct Tooth belt" at 158T (159T would be perfect) which will not fit with the 16V tensioner. You must use the 20V variant which allows you to use the 158T belt.
Here are two ideas that I had for mod'ing the 20V tensioner to make it "Fixed" instead of the hydro self-adjusting. Even though I am not running dist, I may still use the 20v type pictured and "affix it" as shown.
Option #1
Click to Enlarge:



Option #2



Modified by sdezego at 5:24 PM 1-2-2007
 

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Discussion Starter · #41 ·
Re: (WolfGTI)

sorry, I have been very busy here on the text reading your updates and googling, thus no time to work on mine

Actually I have made some progress of sorts. I ordered a crap load of misc parts, factory bolts, studs, elec connectors etc that should be here any day.
In addition, I took the 9a and ABA oil pumps apart to compare the internals, and as suspected, everything is interchangeable. The only difference is the Splined drive shaft on the 9a as opposed to the Forked one on the ABA. I will show some pics just for the heck of it.
So the definite plan "now" is to run the 60-2 trigger on MSnS-e as opposed to Dist. So, I am going to swap out the Modified ABA IM shaft and Cog for the 9a. Didn't put the oil pump in or pan on yet, so this is no biggie.
I have also been trying to decipher whether the 60-2 pickup I have from the ABA that I have will play nicely with MS. Seems to be some conflicting info out there and I don't own a scope.
I have also been doing some wiring or sorts
Hooking up a new Tig in my garage and honing my skills. Lots of stuff to put this to good use on!
Shawn




Modified by sdezego at 6:31 PM 1-2-2007
 

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Discussion Starter · #44 ·
Re: (d-bot)

You have pictured an internal Waterpump and a short block and therfore there are numerous OEM VW belts. For the ABA (Tall Block) Running Dist, there is no belt that will fit using the 16V tensioner (OEM or custom cut). 159T would be perfect and would allow the use of the 16V tensioner, but there is no such belt. So, you must use a 158T which requires the use of the modified 20v tensioner

Edit: No Belt with the Correct Tooth Profile. Nice setup BTW!
S


Modified by sdezego at 4:41 PM 10-11-2006
 

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Discussion Starter · #45 ·
Re: (sdezego)

very slow progress. Too many other projects and such, but should have the rest of the bottom end buttoned up tonight.
in the mean time here are some pic of the Oil Pump.
In case anyone is planning on changing directions Mid stream as I did (Dist vs COP or WS) or in case you just enjoy saving a few $s, here is a tip.
If you plan on running the 16v Oil pump drive Gear and dist block off setup you can swap the Shafts from an old 9a oil Pump into the much less expensive ABA oil pump. I don't think the 16v PL has the recess notch on the Oil pump shaft becuase it does not have clearance issues as the 2Liters do, but irregardless.
Pics tell the story. oh, yea, you MUST have a press!
Click pics to enlarge:



 

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Discussion Starter · #46 ·
Re: (sdezego)

Another week out of town on business, but made some progress in the machine shop today. Here is my way of modifying the ABA serp pulley for the wider 16v/20v belt.
- Total cut was ~5.8mm
- .001" press fit
- perfectly eccentric and uses stock crank centering

- perfectly balanced
Click for larger pics:


 

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Discussion Starter · #51 ·
Re: Project Build: sc2020 (G60ING)

Quote, originally posted by G60ING »

You don't think that will cause routing problems for the IC and air filter?
Have you thought about running an OBDI aba TB?

Yea, that was the only one I had at the time from a spare motor. Since that pic I did get up an OBD1 ABA TB http://****************.com/smile/emthup.gif
I really haven't finalized the routing design just yet, but I have a plan and a fall back plan.
My Main Goal is to keep a nice compressed flow out of the charger down into the FMIC (Drivers side) and then from the FMIC P/S up into the TB.
Having the air filter on the PS might be a bit tricky to route and probably impossible with the stock air box, but running the Eurosport Coolflow and a K&N looks doable.
I really want to go back to the stock air box, so I may run the air box on the Driver's side where the battery is and trunkmount the batt.
I also plan on making the charger bypass mechanical from the stock G60 butterfly/Bypass welded onto a pipe just before the TB.
Shawn
 

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Discussion Starter · #55 ·
Re: Project Build: sc2020 (G60ING)

Quote, originally posted by G60ING »

That's what its all about reasonable power with an awesome sound http://****************.com/smile/emthup.gif http://****************.com/smile/emthup.gif

http://****************.com/smile/emthup.gif Most Definitely. And I think that SuperSprint Header with this setup is going to help things sound very healthy


----
Progress is being made, just not at the pace that I would like. Many other distractions including installing Megasquirt on my current setup to get it tuned and any bugs worked out as well the recent acquisition of another G60-> http://forums.vwvortex.com/zerothread?id=2974793
...oh, yea and various things in life (all good). Kids are definite Time Burglars, but they're worth it
 

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Discussion Starter · #57 ·
Re: Project Build: sc2020 (G60ING)

Quote, originally posted by G60ING »
I picked up an NA 20V header manifold

That was my first option, but at the time no one wanted to sell one at a decent price. Also, when I picked it up timing was right to drop coin on the SS header and it was aplenty. Still going to take fab work to Reflange it and make it fit too.
 
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