How do you Rebuild a 16v

[GoLfMan]

If you dont want to go crazy with the rebuild GolfMan, a lot of the parts are the same as an 8v motor. Headgasket and Rings for example.

You could hone the bores, put new rings and then do some headwork, port and polish and a skim. You`d end up with a nice rebuilt motor, but wont have spent silly money.

If you start buying pistons and resleeving blocks it gets expensive. Even a stock kr engine in a Mk1 is gonna haul ass.

Throttle bodies are very expensive, use factor fuel injection, or go aftermarket. Fuel is never gonna get cheaper.

thanks for that info Loon. Porting, Polishing and port matching should release a few more killowatts. What about grinding the cams to a more agrressive lift?
what do i need for a injection conversion?

[Golf Loon]

Gav was saying you can use two exhaust cams in a kr head and that gives more mid range power.

Fuel Injection you need a diesel fuel tank and bigger fuel lines and a fuel pump to suit the application. You need different pumps for kjet and aftermarket. If going aftermarket computer, you can use a cheaper fuel pump

[GoLfMan]

Gav was saying you can use two exhaust cams in a kr head and that gives more mid range power.

Fuel Injection you need a diesel fuel tank and bigger fuel lines and a fuel pump to suit the application. You need different pumps for kjet and aftermarket. If going aftermarket computer, you can use a cheaper fuel pump

so how much all up would be the tank, lines and pump etc and how hard to install?

[ausgolfer]

Gav was saying you can use two exhaust cams in a kr head and that gives more mid range power.

Fuel Injection you need a diesel fuel tank and bigger fuel lines and a fuel pump to suit the application. You need different pumps for kjet and aftermarket. If going aftermarket computer, you can use a cheaper fuel pump

You need a modified chainwheel to do the twin exhaust cam mod, mine arrives in 2 weeks.
I don't see the point in modifying your engine to give more power, and then using cheap fuel(debatable weather it gives you worse economy also).

[GoLfMan]

did you miss-read mate? its cheaper fuel pump...
but yes i also agree that modifying your engine then using **** fuel is useless... its like putting water on a fire really.

back to it!
so why do you need a modified chainwheel?

[ausgolfer]

ha ha I did miss read, sorry must be getting tired

and the modified chainwheel allows u to use the differently timed echaust cam in the place of the inlet cam.

[GoLfMan]

ahh awesome...
so the cam set up in a 16v is good enough already that getting a set of high lift cams for it is not that usefull?

[ausgolfer]

well the standard cams in the KR are good but the intake has slightly less lift than the exhaust, hence this mod that many including I am doing, and they should be good for upwards of 180hp(in a 2L must be said) if you went all out with exhaust and porting.

[Valver.]

Hey Valver, I know you've had ABF's in the last 2 cars but do you know where I could find 83mm or 83.5mm pistons for a KR? All the aftermarket 16v pistons I could find were for 9a's or ABF's, except for the ones TSR used to sell in the 1.8KR to 1.9KR rebuild kit

Wössner make them --> http://www.woessner-kolben.de

They're all listed in 12.7:1 spec, but they make anything - they're forged and expensive, though - 178 Euros each:


VW Golf 2 GTI 1.8 Ltr. 16V 9029D050 KR 82 12.7:1 10.0:1 4 0.08 mm 820XSY WP052 CW20 178
VW Golf 2 GTI 1.8 Ltr. 16V 9029D100 KR 82,5 12.7:1 10.0:1 4 0.08 mm 825XSY WP052 CW20 178
VW Golf 2 GTI 1.8 Ltr. 16V 9029D125 KR 82,75 12.7:1 10.0:1 4 0.08 mm 827XSY WP052 CW20 178
VW Golf 2 GTI 1.8 Ltr. 16V 9029D150 KR 83 12.7:1 10.0:1 4 0.08 mm 830XSY WP052 CW20 178
VW Golf 2 GTI 1.8 Ltr. 16V 9029D200 KR 83,5 12.7:1 10.0:1 4 0.08 mm 835XSY WP052 CW20 178
VW Golf 2 GTI 1.8 Ltr. 16V 9029DA KR 81,5 12.7:1 10.0:1 4 0.08 mm 815XSY WP052 CW20 178

Mahle will make the same pistons in cast, but youd have to enter an enquiry locally. The Aus. dealer is:

MAHLE Engine Components Australia Pty Ltd.
2 - 8 Oxford Rd
3026 Laverton North, Melbourne

Phone +61 (0) 3-83 68-18 88
Fax +61 (0) 3-83 68-18 04

[Valver.]

ahh awesome...
so the cam set up in a 16v is good enough already that getting a set of high lift cams for it is not that usefull?

If you get a KR code engine and not a PL. The PL only has 123hp, vs 139 (often closer to 150) in the KR.

The inlet cam is really soft on the PL.

Regrinding the cams can't help the lift much - it can only lenthen the opening duration. It's not much good going overboard with cams on a 16v unless the head is really nicely done -> been there, and learnt that very quickly!

Remember you also need a better gearbox, clutch setup and flywheel, so that has to be factored in.

EDIT: re the fuel injection swap: it's going to be much easier to convert to EFI, compared to sourcing the parts for CIS. Not only will it run smoother and perform better, it's also cheaper to do. There are so many guides online about putting MegaSquirt'n'Spark standalone in a Mk1 16v that you could do it yourself and input the map easily.

If you buy it from Patatron.com, especially.

I'm really happy with my EFI setup - it uses a diesel tank and lines, which I pressure flushed; a VL turbo and pierberg fuel pump setup and a swirl pot. Using the pre-pump meant I have a pre-filter before it and also another main filter to protect the VL pump. It was expensive, but you could be done for much less if you wanted to