2 ltr conversion....what do I need?

[TwistedAspect]

Hi peeps,

Biting the bullet here. I currently have a PB (Digifant) engine setup in my motor and want to go the whole hog with a 2ltr conversion, including a gasflowed head, high lift cam, chip and induction.

Can someone give me a list of what I need to buy?

[silkyballs]

you dont need that much dude mainly just a 2ltr bottom end!oh and another head that you can send off to be gas flowed etc.apart from that everything you have already is all you need.

[TwistedAspect]

Hmmmm...that may be the case but which bottom end would I need?

I also thought you had to convert the gearbox over to a 16V, including the clutch if you converted from a MK3 8v Bottom end?

I could do with a shopping list to be honest...anyone care to assist?

Jay

[rubjonny]

While its still fresh in my head:

Timing belt from whatever bottom end you get i.e if its a MK3 2e, you'll need a 2e belt.
Anxilery belts for the bottom end you choose, unless you strip em all off and refit the MK2 stuff (I'm using the MK3 anxileries)
Head bolts
2e Metal head gasket
Inlet & zaust manifold gaskets
Rocker cover gasket, if possible get the MK3 rubber gasket conversion kit
16v/G60 rear engine mount
Synta Silver oil
Oil filter
Sump plug seal
New metal water pipe
Zaust manifold studs & copper nuts
Clutch kit including: Pressure Plate, friction Disc, Release Plate, Clamping Ring, special grease for input shaft and new bolts
Gearbox input shaft seal, pushrod bush & end seal
Some spare coolant

New plastic flanges, ideally get a 2e front flange as this will then allow you to use all the MK3 coolant hoses.  You'll have to blank off the small hose to the header tank at the radiator end, as on the MK3 the header tank hose goes to the plastic flange on the front.  It also has sparky wire clips on it so neatens everything up nicly

[Devon Joe]

The 2.0 8v '2E' bottom end is in Passats- plenty of them in scrapyards, just check its a 2.0 first. The block has a big '1.8' or '2.0' cast into it so its easy to spot if you can find it..

rubjonnys list is spot on- it sounds a lot but he's been thorough and put sensible stuff like new manifold studs/copper nuts (which i now so wish i'd done to mine...rusty,rounded off nuts, sore knuckles etc etc)

The extra torque may knacker your front engine mount- my 2.0 16v conversion broke one in only a few months but a spangly solid CNC alloy one from ...joe sorted that out!

[rubjonny]

Yeah I'd replace all the engine mounts while you're there, but you want to put the 16v/G60 rear one on at the very least as its such a sod to get to once the engine is in!  Try out a set of bonded rubber 1.3 gearbox & front mounts first, if that aint good enough then a solid front one as said from Joe or Mr.Brown

One thing I forgot to mention was the dizzy, the 2e lump is easiest for the MK2 digi conversion as the dizzy will just plug in and work.  If you get an Audi 2.0 lump, you'll have to fit your old dizzy to it.

Then you have to think about the clutch/gearbox setup, I went with a 16v clutch/gearbox as there was one going cheap locally at the time.  You can swap an 8v clutch into it and reuse your old flywheel though.

[steviem]

Whats wrong with using a normal 8v gearbox?

[rubjonny]

Nothing, I meant to say 'and re-use your existing gearbox'

At the time the 16v box came up I thought this was the same box as fitted to the MK3 GTI, but it turns out although the input shaft is the same (larger, more splines) The gear ratios are different.  It was cheap and what I could source locally

[steviem]

ok, cool..

[silkyballs]

 bahn brener do a wicked solid engine mount and they are only £65 including postage!!!