project stroker 2.0 BAT build

[a408]

hey guys, first off this is my very first real project. so bare with me as i am a 20 year old college student on a budget and as much knowledge i can get from these forums. I'm currently running a full frame GT2871r setup with all the supporting goodies getting around 280whp on 91oct pump. i Recently picked up some parts to get my 2.0 build going. Still undecided on most of the parts so any help is greatly appreciated

My plans for this car is to have about 400whp for some spirited driving, a couple track days a year, and possibly take it to the drag strip when it is all done. I'm doing this project more for learning about my car and cars in general. I learned a tremendous amount after doing my 2871r swap and had a blast. even though it was a headache, lots of time without my car, and countless $$. and i know that this next build is going to be even more of a headache, more $$ and most likely a lot of time without my car. I'm going to take what i have learned from other peoples build threads and my past experiences and do this the right way. I plan on building the spare motor, bottom and top. then getting the turbo/mani/dp/etc all together and assembled for the most part. When i have everything i need, then i swap the motor and take the car to 034 motorsports for the tune.

keep in mind this is going to be a SLOW build. i am in no rush whatsoever to cut some corners and get it done. i want it done right so i don't have to do it twice. i'm very excited and hope this thread will give me great pointers and advice

These are the parts i currently have for the build:
-06A bare block
-AEB Head with ST Inconel valves and ST valve springs with Titanium retainers
-AEB intake manifold
-Scat 144mm Rods with 034 Calico rod bearings
-Supertech pistons 83mm for 2.0
-ARP main studs
-Tial 38mm wastegate

What i still need to purchase for the engine (please let me know if there is more needed)
-Machine shop bore/balance
-Oversized 83mm head gasket
-Head stud kit
-Fuel pump (bosch 040, 044, Walbro 255lph??)


Turbo and everything else - i am not completely sold on the following, so anything i should know, or other recommendations are welcome
-Custom Tubular manifold and downpipe made by kyle (JK35)
-Precision PTE5857SP .63ar
-630cc injectors
-034 me7 custom tune
-Southbend stage 4 clutch w/fidanza lwfw


on to some pics

[AudiA4Turbo22]

psi concepts manifold FTW

[SleeperAvant]

nice

[Audi Skate Snow]

psi concepts manifold FTW

x10000

I have it on my car and fuckin love it.

[kneel]

psi concepts manifold FTW

about to add one to my car. Jeff said it will ship out tomorrow! woot

[FORCE_FED_DUB]

why the 058 block?

[black99.5a4]

the 058 block is doing it the hard way. you are going to need the aba crank, get the intermediate shaft sprocket machined down and the oil gear has to be clearanced for most aftermarket rods.

[vintagespin]

I'm confused. You said you have a built AEB head ("AEB Head with ST Inconel valves and ST valve springs with Titanium retainers") yet you still say you need a built head...

[stilly_a4]

Good luck! Subscribed!

[A4 TSCHUSS]

058 has the clearancing inside the block that needs to be done which sucks. It needs the intramural shaft mod done which sucks. It has an external water pump and a belt driven fan that connects to it which our cars (06a block) use internal water pump and electric fan.

[a408]

I'm confused. You said you have a built AEB head ("AEB Head with ST Inconel valves and ST valve springs with Titanium retainers") yet you still say you need a built head...

edited. typo

[black99.5a4]

fuel pump, i'd go the bosch drop in from 034 for the b6.. it use to be the bosch 005, but i heard they stopped making them.. not sure if that is true or not.. if it is i dont know what 034 is using now.

[dougyfresh]

the 058 block is doing it the hard way. you are going to need the aba crank, get the intermediate shaft sprocket machined down and the oil gear has to be clearanced for most aftermarket rods.

yes

waste of time for a B6.

go find an 06A block.

[a408]

yes

waste of time for a B6.

go find an 06A block.

well i already bought the 058. i also have a spare 058 that is bored to a 2.0 with the ABA crank with the IM mod done to it already. so that saves me most of the work.

[A4 TSCHUSS]

well i already bought the 058. i also have a spare 058 that is bored to a 2.0 with the ABA crank with the IM mod done to it already. so that saves me most of the work.

Did you miss this part? The block is setup different for the water pump. Ours goes inside the block as opposed to a big cavity with pump attached to it that bolts outside the block for the 058.

It has an external water pump and a belt driven fan that connects to it which our cars (06a block) use internal water pump and electric fan.

[Dan[FN]6262]

yes

waste of time for a B6.

go find an 06A block.

Did you miss this part? The block is setup different for the water pump. Ours goes inside the block as opposed to a big cavity with pump attached to it that bolts outside the block for the 058.

X2

[A4 TSCHUSS]

Pretty sure the thermostat housing setup is all different as well so hoses may not line up that connect from the car and the final thing is will the bracket for the accessories (alternator,a/c,power steering) bolt to the block also? The accessories are in completely different spots in the b5 a4 using that older block.

[a408]

Pretty sure the thermostat housing setup is all different as well so hoses may not line up that connect from the car and the final thing is will the bracket for the accessories (alternator,a/c,power steering) bolt to the block also? The accessories are in completely different spots in the b5 a4 using that older block.

Ohh i see. yeah that seems like it's going to be a headache when doing the swap. i wasnt thinking about that when i got the block so you think it is a complete waste?? i should just buy an 06A block or pull mine, take it to the machine shop, then assemble?

thanks guys

[A4 TSCHUSS]

Yes getting the incorrect block for your car was a waste. Get rid of them and get the right one and build it and don't think about taking your car apart until you have every last bolt and gasket in your hands to complete the swap.

[a408]

Yes getting the incorrect block for your car was a waste. Get rid of them and get the right one and build it and don't think about taking your car apart until you have every last bolt and gasket in your hands to complete the swap.

sounds good. will i still be able to use the ABA crank with the 06A?

[f15046]

You need an AEG crank to go 2.0 with an 06A block.

[black99.5a4]

there is a local guy to me selling his complete 06a motor (01 a4) for 150 bucks if someone pulls it themselves... it could really help a local out, or if you put up some $$ someone might pull it for you.. it was a sludge motor and the vvt tensionor let the chain eat the guide, but no damage was done to the head or anything.. just needs hot tanked/cleaned out/rebuilt and a ne wVVT tensionor.. still not bad for 150 bucks.

[A4 TSCHUSS]

Yeah I have an AEG crank which has an oil pump sprocket on it to run the pump in the 06a since it is chain driven instead of the shaft like in 058 block.

[dougyfresh]

I have an AMB (06A) complete shortblock that I can sell you. Just have to pay the freight shipping across the country.

[A4SoftWalker]

The journey begins - Gud Luk with ur build

[a408]

i talked to 034 with my issue. they said it really isnt going to be THAT bad is i keep the 058. since i already have all the accessories, new oil pump, water pump ect.

i just need to buy some thermostat housing from a AEB motor and a couple misc things here and there. but in the mean time i will keep my eye out for a 06A block, and purchase my mani/turbo parts

[black99.5a4]

oil coolers mount different to the block (058's will have a oil temp sensor spot you need to leave plugged in and not connect to, or plug it with a plug)

breather hoses in the side of the block are different

thermostat housing

also the cooling port on the side of the block.. below the intake.. 06a is a big circle, 058 is a bolted on piece.

[a408]

oil coolers mount different to the block (058's will have a oil temp sensor spot you need to leave plugged in and not connect to, or plug it with a plug)

breather hoses in the side of the block are different

thermostat housing

also the cooling port on the side of the block.. below the intake.. 06a is a big circle, 058 is a bolted on piece.

this is all great info and i really appreciate it all. it definitely seems like it's going to be a headache, but if i have to do it, it can be done. for right now i found a 06A from a jetta that might work. I'll be checking it out within the next few days when i have time. it's from 034 and it's a fully built 2.0 bottom end. ill get the specs when i can.

that would definitely save me a whole bunch of problems and that combined with the built AEB will be a great turnout.

[RecklessTuning]

I use the FSI 2.0T crank with the AWD 1.8t Oil pump gear and it's the only way to go in a 2.0 stroker engine. Trust me I have built a lot of these. Go with the 06A block and save your self a worlds of trouble.

Also words of advice. If you're actually going to get this thing running. Make sure you cut out clearance on all for pistons for the oil squirter's. No one ever believes me but when you get your engine back together and you start ticking, dont say I didn't tell you so.

[FORCE_FED_DUB]

I use the FSI 2.0T crank with the AWD 1.8t Oil pump gear and it's the only way to go in a 2.0 stroker engine. Trust me I have built a lot of these. Go with the 06A block and save your self a worlds of trouble.

Also words of advice. If you're actually going to get this thing running. Make sure you cut out clearance on all for pistons for the oil squirter's. No one ever believes me but when you get your engine back together and you start ticking, dont say I didn't tell you so.

bad/incomplete advice here. there are multiple ways to make a 2.0L, you only posted one. the fsi crank is not needed, the aeg crank is just fine. and it doesn't have to be an awd oil pump gear.

make sure there is clearance between the oil squirters and piston skirts, but don't just go hacking at them "to make sure".

[A4 TSCHUSS]

No cutting on oil squirters needed and aeg crank is more than good enough and has been used countless times on 500+whp 1.8t engines. And that is how my engine is as well at 20,000 miles now since boring/stroking it.

[Issam@INA]

i talked to 034 with my issue. they said it really isnt going to be THAT bad is i keep the 058. since i already have all the accessories, new oil pump, water pump ect.

i just need to buy some thermostat housing from a AEB motor and a couple misc things here and there. but in the mean time i will keep my eye out for a 06A block, and purchase my mani/turbo parts

Who did you speak to at 034?
I highly doubt Javad or anyone at 034 would advise you to go back in time to an 058 block.
Get an 06A block, source an AEG crank and use whatever pistons and rods you got.

You will spend MORE in the machine shop:
Machining the im shaft
clearancing the walls of the block
clearancing the oil squirter

than you would simply BORING a 1.8T 06A/06B block.

Coupled with the fact that the accessories are all haywire.

Do NOT use an 058 block.

[dougyfresh]

No cutting on oil squirters needed and aeg crank is more than good enough and has been used countless times on 500+whp 1.8t engines. And that is how my engine is as well at 20,000 miles now since boring/stroking it.

To build on this...

The 92.8mm cranks don't come near the oil squirters. You do need to verify clearance with the squirters and the overbore pistons. I think Supertech pistons do not come clearanced unless the vendor clearances them prior to receipt by yourself.

[A4 TSCHUSS]

I have Supertech pistons. Nothing was done to mine.

[Issam@INA]

I think Supertech pistons do not come clearanced unless the vendor clearances them prior to receipt by yourself.

Depends when they were ordered. I know the first batch of stroker pistons produced did not have the clearance for the oil squirters even though they claim they did. Martin did get it right on the 2nd batch but it was not enough for some of the "special" blocks.

[a408]

small update:
-i put the built 058 2.0 block for sale and have a pretty serious buyer that will locally pick it up this week. I'm currently looking for a 06A block, and 2.0 crank. im getting the rods and pistons through 034 motorsports most likely.

-I'm pretty sold on going with the PTE5857 turbo. not sure if i want to spend the extra $450 on going ceramic BB or not. if someone can tell me if its really worth it that would be great.

-Also pretty sold on going with the Agtronic manifold/DP as soon as i find out it will work with the pte turbo.

ITEMS for sale if anyone is interested
-058 stock block with oil pan
-AEB stock head

both in great working condition

[dougyfresh]

Depends when they were ordered. I know the first batch of stroker pistons produced did not have the clearance for the oil squirters even though they claim they did. Martin did get it right on the 2nd batch but it was not enough for some of the "special" blocks.

April 2007

In addition to them needing to be notched for the oil squirters they were also not manufactured to spec and both the factory and vendor I got them from did not catch this. However, I am not going to get into that one right now...

[Issam@INA]

small update:
-i put the built 058 2.0 block for sale and have a pretty serious buyer that will locally pick it up this week. I'm currently looking for a 06A block, and 2.0 crank. im getting the rods and pistons through 034 motorsports most likely.

We have alot of 92.8mm cranks both cast and forged.
Send over a PM if you are interested.

[black99.5a4]

the stroker pistons for the b6 (supertechs) are notched... infact, the box was sharpied "95.5" on it, so I am assuming Bob probably went over them for even more clearances.

[dougyfresh]

the stroker pistons for the b6 (supertechs) are notched... infact, the box was sharpied "95.5" on it, so I am assuming Bob probably went over them for even more clearances.

I would not assume that. Measure everything and trust no one.