Getting a project car soon and want to do the 1.6 conversion after reading the thread about it i still have a few questions if anyone could help me out.

1) Cut and shut the inlet manifold or use a mk1 head?

2) Gaz said 'the block is taller, so the downpipe needs to be lengthened by about 1cm.' I will be using a fourbranch and a custom exhaust so I'm guessing its prossible to just make the centre pipe longer?

3) How many bhp does the 1.6 put out? Is it 75 or 100?

4) Is it possible to get 120bhp from the 1.6 with the following mods

Ported and polished head + Throttle body

Suitable cam

Full performance exhaust system with four branch decat

Uprated injectors

GT ECU with chip

5) Also Gaz mentions the GT cam doesnt line up properly with the 1.6 timing marks, how is this fixed just working out the difference in distance?

Thanks

Ash

Getting a project car soon and want to do the 1.6 conversion after reading the thread about it i still have a few questions if anyone could help me out.

1) Cut and shut the inlet manifold or use a mk1 head?

2) Gaz said 'the block is taller, so the downpipe needs to be lengthened by about 1cm.' I will be using a fourbranch and a custom exhaust so I'm guessing its prossible to just make the centre pipe longer?

3) How many bhp does the 1.6 put out? Is it 75 or 100?

4) Is it possible to get 120bhp from the 1.6 with the following mods

Ported and polished head + Throttle body

Suitable cam

Full performance exhaust system with four branch decat

Uprated injectors

GT ECU with chip

5) Also Gaz mentions the GT cam doesnt line up properly with the 1.6 timing marks, how is this fixed just working out the difference in distance?

Thanks

Ash

1) Cheapest way is to mod the inlet

2) Longer centre section

3) 75bhp

4) 120bhp is possible

5) Aftermarket cam preferable

Thanks Ema, 86c & Gaz

Aha, missed this thread.. can anyone clarify these final Q's...

Will the 1.6 AEE block bolt upto the 1.3 heads (3f and so on)

if not

Will the inlet from the 3f ( or twin 40 mani that fits one, as i really want to know) fit the AEE head or do i have to buy another! :( I know the exhaust fits though

Does the AEE block have the same mounting on the rear of the block (bottom left hand, 3 bolts) if looking from into the bonnet...?

Dont think you can you use the 3f head because it would create too much compression! But it might bolt up.

And the 1.6 bolt pattern is different to the 3f inlet as well.

fuck lol

Thats proper annoying - doubt i'll be able to find a 40's maniffld for the AEE head? Don't want the wait to get bike carbs and mani made!

Does anyone know if it's the same pattern as anytingn else that i may be able to get a manifold for and use it on the 1.6?

Edited 13 May, 200818 yr by twin40racer

Yeah its the downside to the thing theres also a few more problems but thats the main one.

Your best bet would be to get the head welded and modded to fit the 3f bolt pattern. Emal ema off here, her boyfriend can do it.

wierd, the manifold that Joel has made for an AEE and the gasket for a 1.3 head look the same pattern... are they further apart/closer or somthing? :(

Here to fit AEE:

and grabbed off vagcat, NZ inlet...

Edited 13 May, 200818 yr by twin40racer

They are definately different.

Righto, Gaz, have you any idea where i could get a manifold to run 40's on an AEE

Gaz did the AEE engine come with air con? is it possible to keep the air con and put it in the mk3 polo?

Not many mk4s came with air con, just some late 16v models I think. I can't say for the other cars it was in (golf, ibiza, felicia, etc) But it's pretty tough to get air con in a mk3 as there's not alot of room behind the dash. I think there might be an issue with it staying on the block as well as the Air con, PAS unit and alternator are on a cradle that has to be removed to fit the mk3 engine mount.

can i use the same thing to mky mk4 8v, as in put a 1.6 bottom end on ?

or am i being silly

From what I've seen the way the serpentine belt runs on the 1.6s you wouldn't get it in a mk3 due to chassis leg clearance

^^ you talking to me??

i got a mk4 1.4 8v ( just like ever fucker lol )

You should just be able to swap the complete engine and gearbox on a mk4 with no issues.

more questions for the oracle that is Gaz

1. bottom alternator belt pulley on an ABD is toothed not a V-belt? are the pulleys a straight swap?

2. abd block, 8p gearbox. Which flywheel/clutch?

3. i want to use my 2G head and cam to keep the mech fuel pump, is the cam pulley from the ABD head going to fit my 2G camshaft?

4. finally, anything else i should know, i read this whole thread and it says the ancillaries from a GT swap straight over. so no quibbles with engine mounting holes not being there or starter motors not fitting etc etc.

cheers buddy

use polo pulley

if flywheel looks really thick (late abds and those fitted to ibizas), swap with polo otherwise it's the same

Cam pulley will fit fine use the ABD pulley on the 2G head.

Engine is the same outside as 1043 and 1272 so no issues whatsoever. :)

Ok I'd ideally want to run an 1600 block in my car next year.

few questions:

1) I read somewhere you can bolt on the 1300 sump to allow clearance for the zorst manifold. is this true?

2) Could you weld some extra material onto the head where the missing inlet bolt holes are, file it down and drill/tap as necessary? Or would you hit something with the drill?!

3) Is it ok to use mk2 standard 1300 ignition on the 1600 lump?

Many thanks to anyone who can answer

1) you can grind a small amount off the block and use the same sump - or at least a friend did.

2)

3) Yep, that will work...!

The sump is much wider on the 1.6,as is the block (you'll have to use the thinner starter and thus late type flywheel),to allow for the ridiculous 86mm crank stroke. But the 1.6 sump has the same exhaust clearance anyway,so why would you wanna use a 1.3 one? Only the reservoir is deeper,which is aside the exhaust.

Just to update on my last post,which i wrote a year ago (or post hijack - soz Gaz My 1.6 bike-carbed MK2 coupe is now a 1.4 bike-carbed MK2 coupe. Its now a non-sunroof shell,but otherwise I'm able to make a precise comparison between using the 1.6 AEE and 1.4 ABD with the same carbs. Result? The 1.4 is a better drive. More balanced,more progressive,and almost as quick as its more tractable.

Edit - A year on,and its now an AFH-based 1.6 16v. Couldn't resist..

Edited 27 August, 200917 yr by MikeyMK

thats good to hear, since i'm currently putting an ABD into my mk2 golf (with dellorto's/4 branch /system/268)... which would be now done if i hadn't cracked the block putting it in with a stupid error... An 085 box does fit an ABD block? So it's on hold until i can get it welded, or it's back to a 3f block - which also needs welding

The sump is much wider on the 1.6,as is the block (you'll have to use the thinner starter and thus late type flywheel),to allow for the ridiculous 86mm crank stroke. But the 1.6 sump has the same exhaust clearance anyway,so why would you wanna use a 1.3 one? Only the reservoir is deeper,which is aside the exhaust.

I've never seen an AEE block so I'm just going on what people tell me!! And I have a 1.3 4 branch I want to use... Anyway reading your posts has made me think an ABD block might be worth thinkin about instead...

http://www.clubpolo.co.uk/forum/index.php?showtopic=109565

The sump is quite abit bigger then the polo one. Shouldnt bother me because I'm only going down 40mm

If your going for carbs 1.4 abd might be best. Seems the AEE works best on injection

I was actually planning on using the DMTL with the 1.6 driver standard jets and a GK inlet manifold. It could work quite well I think...