2.0L ABA Conversion into a MK2
This is a broad overview of the parts that are need or can be used to perform an ABA 2.0L Crossflow engine swap into an MK2 Volkswagen. The following list is based on personal experiences with these swaps and information gathered online. There may be some incorrect information or missing information in this thread, if you know for a fact that something is incorrect or have other options that work that I have not listed please contact me and I will edit the post.
The Crossflow swap can be done with very basic components and can retain most MK2 original parts, or it can be done as a conversion to an almost complete MK3 engine bay. I have listed many options, but there are always more out there. This is by no means a bible on how every swap should be done but more of a reference for people with questions or starting out.
Please respect this post and IM or email me with changes you think should be made. Let’s keep this clean and factual.
IF you are looking for reference on:
Automatic to Manual Transmission conversions
Brake Upgrades
Converting to CE2 from earlier wiring
YOU WILL NOT FIND IT HERE….. USE THE SEARCH FUNCTION, THERE ARE TONS OF TREADS OUT THERE ALREADY
Enjoy,
Smokinjoe644
PARTS
Minimal Parts Needed:
1) Complete ABA Engine assembly
2) Engine bay wiring harness
3) ECU
4) ABA Coil
5) MAF sensor
6) MK2 rear motor mount bracket (if using MK2 K-frame)
7) MK2 transmission
8) MK2 throttle cable from Digi2 vehicle (1990-1992)
9) MK2 speedometer cable
Other Parts (application specific or options):
1) Down pipe and Cat (depending on previous setup, and number of O2 sensors)
2) MK3 K-frame (can be substituted for MK2 K-frame, then MK3 rear mount is retained)
3) MK3 Trans (not needed but may provided better gearing)
4) MK3 or Late MK2 Coolant bottle (allows for direct connection to MK3 wiring w/o splicing)
5) MK3 washer fluid pump (allows for direct connection to MK3 wiring w/o splicing)
Additional accessories:
1) PS Steering (MK2 lines will fit the MK3 pump if you remove the banjo bolt fitting, otherwise MK3 lines can be used and will mate to the MK2 rack)
2) AC delete (use VR6 pulley to replace ABA water pump pulley, new belts are needed *futrell autoworks sells complete kit with belts)
3) AC installed (easiest to use MK3 parts, corrado lines can be run as well *heater core or box may need to be changed to accept new lines)
4) ABS (MK3 ABS is self contained and is an independent wiring harness)
ABS INSTALL
a) MK3 booster/master/abs assembly can be mounted with
existing MK2 bracket.
** if using the MK3 booster the end will need to be
modified to mate to the MK2 pedal
b) Front MK2 lines will need to be modified or MK3 lines can
be used (holes need to be drilled in strut towers *MK3
lines go through the towers not under them)
c) Rear MK2 lines will need to be modified or MK3 lines can
be used (use late MK2 or any MK3 rear beam for easiest
installation *brake lines connect to beam directly not to
the body as in early MK2 cars
d) ABS Wiring will require a second hole to be make in the
front of each strut tower, and two holes to be made under
the rear seat
e) An additional hole may need to be made in the firewall
depending on vehicles original equipment
INSTALLATION
Engine Bay Preparation:
Suspension:
1) Use MK2 original K-frame ** MK2 rear motor mount bracket will need to be used on engine
2) Use MK3 K-frame ** direct replacement for MK2 K-frame, use MK3 rear bracket
3) All other suspension components can remain the same, stock MK2 or aftermarket
4) Use MK2 front cross member ** does not need to change
Steering:
1) Use stock MK2 power or non-power rack and/or lines ** banjo fitting will need to be removed from MK3 PS pump to install MK2 hard line
2) Use MK3 rack and/or lines ** lines can be used with MK2 rack
Cooling bottle:
1) Use stock MK2 rectangular bottle ** level sensor plug will need to be spliced into MK3 wiring
2) Use stock MK2 round bottle ** direct fit
3) Use MK3 bottle **direct fit
*** if updating from the rectangular bottle to the round bottle, the original bracket needs to removed and a bolt-on bracket can be used from late MK2s that had the round bottle***
Washer fluid:
1) Use stock MK2 pump ** plug will need to be spliced into MK3 wiring
2) Use MK3 pump ** direct fit into MK2 bottles, don’t forget to check single or double outlet
Coil:
1) MK3 coil must be used ** will bolt directly to the factory MK2 holes
Radiator:
1) MK2 stock radiator ** overflow on the passengers side needs to be capped off
2) MK3 radiator (use passat 16V front cross member)
Radiator Fans:
1) MK2 stock fans ** plug will need to be spliced into MK3 wiring
2) MK3 fans
3) Passat fans ** direct fit to MK2 and same wiring as MK3 harness
Radiator Thermoswitch:
1) MK3 switch ** will install into MK2 or MK3 radiator
Brakes:
1) MK2 stock brakes can be used
2) Any combination of Corrado/Passat/MK3 brake components can be used
*** Search for other threads, many variations can be found***
Fuel Pump:
1) MK2 pumps can be used ** some wiring may need to be done depending on application
2) MK3 tank and pump can be installed ** direct fit to MK2 body
Fuel Lines:
1) MK3 rubber line ends should be used to mate to the fuel rail ** will fit onto existing MK2 lines
2) MK3 lines can be installed onto MK2 ** direct fit, best if using the MK3 tank and pump
Emissions:
1) Will vary by year ** especially with OBD2, VW changed things throughout the years
2) Generally, you will need whatever sensors the swap car originally had in place
3) MK2 charcoal canister can be mated to MK3 lines
a) MK3 canister will not fit anywhere easily
b) If MK3 canister had a purge valve it can be tied up and left hanging
Gauge Cluster:
1) MK2 cluster can be used based on interior wiring
a) MFA cluster sensor needed to override speed limiter
** can be added to any cluster
b) Sensor must be installed to eliminate speed limiter
** see engine wiring, speed sensor
2) MK3 cluster can be used with CE2 interior wiring
a) A jumper wire must be used from D8-E2 on the fuse
block to power the gauge cluster
Engine Wiring:
1) Use MK3 engine bay harness
2) ** MK3Plugs may need to be switched for MK2 plugs for the following: (radiator fans, washer fluid pump, brake fluid reservoir, coolant reservoir) Depending on above parts used.
3) Holes will need to be made for the MK3 harness, 2 large holes for the grommets going into the rain tray area
Headlight Harness
4) MK3 headlight harness can be used
a) Best to use is Jetta or Golf with single bulbs for
standard NON-H4 harness; otherwise you will need to
modify it to work for your application
b) Late MK2 big bumper turn singles will be a direct fit to
the MK3 harness
c) Late MK2 side markers will be a direct fit to MK3 harness
d) MK3 horns can be used, or late MK2s
**** MK3 harness is long and will need some fitting ****
Vehicle Speed Sensor
5) MK3 speed sensor can be used in MK2 transmission
a) If not using MK3 VSS ** stock speedometer cable from
MK2 used
b) Use an MK2 gauge cluster with MFA functions, there will
be a small plug on the speedometer side in the rear of
the cluster (usually black).
c) Run a wire from the center pin of that plug to the ECU
wiring T68 pin #65 blue w/ white strip
*** This will remove the engine speed limiter, without
doing this the engine will be limited in all of the
gears to 5500 rpms because it will be looking for the
signal from the VSS which does not exist.***
Ignition Coil
6) MK3 coil will require a ground wire to be run from the ground terminal to the tachometer wiring inside of the vehicle for MK2 gauge cluster.
a)The ground terminal is the bottom post under the cap
(plugs facing passengers side)
b) Run the wire to the green wiring in the gauge cluster
wiring harness for the tachometer signal.
VAG-COM
7) VAG-COM
a) pin #4 and #5 go to ground
b) pin #16 goes to 12V+ (power)
c) pin #7 ECU
MORE WIRING HELP CAN BE FOUND HERE: http://mysite.verizon.net/e.sese/x-flow_swap.html
Engine Preparation:
1) Conversion to NON-AC if desired
2) Switch MK3 rear motor mount bracket for MK2 bracket if using the MK2 K-frame
3) OBD2 throttle body needs to be turned upside down
4) OBD2 throttle body will require a bracket to be made for the throttle cable
a) The original bracket can be tapped into the top of the
intake manifold
b) The cable can be run under the manifold and the
bracket can be attached to the support bracket for the
upper intake manifold (large U-shaped bracket)
5) OBD1 throttle body is left alone
Transmission Preparation:
1) MK2 transmission can be used
a) MK2 clutch disk is required to mate to the transmission
shaft
b) MK2 8V or 16V setups can be used
c) MK3 pressure plate can be used with MK2 disk
2) MK3 transmission no modifications needed
3) MK3 starter can be used with MK2 or MK3 transmission
Modified by smokinjoe644 at 2:25 PM 2-7-2005
This is a broad overview of the parts that are need or can be used to perform an ABA 2.0L Crossflow engine swap into an MK2 Volkswagen. The following list is based on personal experiences with these swaps and information gathered online. There may be some incorrect information or missing information in this thread, if you know for a fact that something is incorrect or have other options that work that I have not listed please contact me and I will edit the post.
The Crossflow swap can be done with very basic components and can retain most MK2 original parts, or it can be done as a conversion to an almost complete MK3 engine bay. I have listed many options, but there are always more out there. This is by no means a bible on how every swap should be done but more of a reference for people with questions or starting out.
Please respect this post and IM or email me with changes you think should be made. Let’s keep this clean and factual.
IF you are looking for reference on:
Automatic to Manual Transmission conversions
Brake Upgrades
Converting to CE2 from earlier wiring
YOU WILL NOT FIND IT HERE….. USE THE SEARCH FUNCTION, THERE ARE TONS OF TREADS OUT THERE ALREADY
Enjoy,
Smokinjoe644
PARTS
Minimal Parts Needed:
1) Complete ABA Engine assembly
2) Engine bay wiring harness
3) ECU
4) ABA Coil
5) MAF sensor
6) MK2 rear motor mount bracket (if using MK2 K-frame)
7) MK2 transmission
8) MK2 throttle cable from Digi2 vehicle (1990-1992)
9) MK2 speedometer cable
Other Parts (application specific or options):
1) Down pipe and Cat (depending on previous setup, and number of O2 sensors)
2) MK3 K-frame (can be substituted for MK2 K-frame, then MK3 rear mount is retained)
3) MK3 Trans (not needed but may provided better gearing)
4) MK3 or Late MK2 Coolant bottle (allows for direct connection to MK3 wiring w/o splicing)
5) MK3 washer fluid pump (allows for direct connection to MK3 wiring w/o splicing)
Additional accessories:
1) PS Steering (MK2 lines will fit the MK3 pump if you remove the banjo bolt fitting, otherwise MK3 lines can be used and will mate to the MK2 rack)
2) AC delete (use VR6 pulley to replace ABA water pump pulley, new belts are needed *futrell autoworks sells complete kit with belts)
3) AC installed (easiest to use MK3 parts, corrado lines can be run as well *heater core or box may need to be changed to accept new lines)
4) ABS (MK3 ABS is self contained and is an independent wiring harness)
ABS INSTALL
a) MK3 booster/master/abs assembly can be mounted with
existing MK2 bracket.
** if using the MK3 booster the end will need to be
modified to mate to the MK2 pedal
b) Front MK2 lines will need to be modified or MK3 lines can
be used (holes need to be drilled in strut towers *MK3
lines go through the towers not under them)
c) Rear MK2 lines will need to be modified or MK3 lines can
be used (use late MK2 or any MK3 rear beam for easiest
installation *brake lines connect to beam directly not to
the body as in early MK2 cars
d) ABS Wiring will require a second hole to be make in the
front of each strut tower, and two holes to be made under
the rear seat
e) An additional hole may need to be made in the firewall
depending on vehicles original equipment
INSTALLATION
Engine Bay Preparation:
Suspension:
1) Use MK2 original K-frame ** MK2 rear motor mount bracket will need to be used on engine
2) Use MK3 K-frame ** direct replacement for MK2 K-frame, use MK3 rear bracket
3) All other suspension components can remain the same, stock MK2 or aftermarket
4) Use MK2 front cross member ** does not need to change
Steering:
1) Use stock MK2 power or non-power rack and/or lines ** banjo fitting will need to be removed from MK3 PS pump to install MK2 hard line
2) Use MK3 rack and/or lines ** lines can be used with MK2 rack
Cooling bottle:
1) Use stock MK2 rectangular bottle ** level sensor plug will need to be spliced into MK3 wiring
2) Use stock MK2 round bottle ** direct fit
3) Use MK3 bottle **direct fit
*** if updating from the rectangular bottle to the round bottle, the original bracket needs to removed and a bolt-on bracket can be used from late MK2s that had the round bottle***
Washer fluid:
1) Use stock MK2 pump ** plug will need to be spliced into MK3 wiring
2) Use MK3 pump ** direct fit into MK2 bottles, don’t forget to check single or double outlet
Coil:
1) MK3 coil must be used ** will bolt directly to the factory MK2 holes
Radiator:
1) MK2 stock radiator ** overflow on the passengers side needs to be capped off
2) MK3 radiator (use passat 16V front cross member)
Radiator Fans:
1) MK2 stock fans ** plug will need to be spliced into MK3 wiring
2) MK3 fans
3) Passat fans ** direct fit to MK2 and same wiring as MK3 harness
Radiator Thermoswitch:
1) MK3 switch ** will install into MK2 or MK3 radiator
Brakes:
1) MK2 stock brakes can be used
2) Any combination of Corrado/Passat/MK3 brake components can be used
*** Search for other threads, many variations can be found***
Fuel Pump:
1) MK2 pumps can be used ** some wiring may need to be done depending on application
2) MK3 tank and pump can be installed ** direct fit to MK2 body
Fuel Lines:
1) MK3 rubber line ends should be used to mate to the fuel rail ** will fit onto existing MK2 lines
2) MK3 lines can be installed onto MK2 ** direct fit, best if using the MK3 tank and pump
Emissions:
1) Will vary by year ** especially with OBD2, VW changed things throughout the years
2) Generally, you will need whatever sensors the swap car originally had in place
3) MK2 charcoal canister can be mated to MK3 lines
a) MK3 canister will not fit anywhere easily
b) If MK3 canister had a purge valve it can be tied up and left hanging
Gauge Cluster:
1) MK2 cluster can be used based on interior wiring
a) MFA cluster sensor needed to override speed limiter
** can be added to any cluster
b) Sensor must be installed to eliminate speed limiter
** see engine wiring, speed sensor
2) MK3 cluster can be used with CE2 interior wiring
a) A jumper wire must be used from D8-E2 on the fuse
block to power the gauge cluster
Engine Wiring:
1) Use MK3 engine bay harness
2) ** MK3Plugs may need to be switched for MK2 plugs for the following: (radiator fans, washer fluid pump, brake fluid reservoir, coolant reservoir) Depending on above parts used.
3) Holes will need to be made for the MK3 harness, 2 large holes for the grommets going into the rain tray area
Headlight Harness
4) MK3 headlight harness can be used
a) Best to use is Jetta or Golf with single bulbs for
standard NON-H4 harness; otherwise you will need to
modify it to work for your application
b) Late MK2 big bumper turn singles will be a direct fit to
the MK3 harness
c) Late MK2 side markers will be a direct fit to MK3 harness
d) MK3 horns can be used, or late MK2s
**** MK3 harness is long and will need some fitting ****
Vehicle Speed Sensor
5) MK3 speed sensor can be used in MK2 transmission
a) If not using MK3 VSS ** stock speedometer cable from
MK2 used
b) Use an MK2 gauge cluster with MFA functions, there will
be a small plug on the speedometer side in the rear of
the cluster (usually black).
c) Run a wire from the center pin of that plug to the ECU
wiring T68 pin #65 blue w/ white strip
*** This will remove the engine speed limiter, without
doing this the engine will be limited in all of the
gears to 5500 rpms because it will be looking for the
signal from the VSS which does not exist.***
Ignition Coil
6) MK3 coil will require a ground wire to be run from the ground terminal to the tachometer wiring inside of the vehicle for MK2 gauge cluster.
a)The ground terminal is the bottom post under the cap
(plugs facing passengers side)
b) Run the wire to the green wiring in the gauge cluster
wiring harness for the tachometer signal.
VAG-COM
7) VAG-COM
a) pin #4 and #5 go to ground
b) pin #16 goes to 12V+ (power)
c) pin #7 ECU
MORE WIRING HELP CAN BE FOUND HERE: http://mysite.verizon.net/e.sese/x-flow_swap.html
Engine Preparation:
1) Conversion to NON-AC if desired
2) Switch MK3 rear motor mount bracket for MK2 bracket if using the MK2 K-frame
3) OBD2 throttle body needs to be turned upside down
4) OBD2 throttle body will require a bracket to be made for the throttle cable
a) The original bracket can be tapped into the top of the
intake manifold
b) The cable can be run under the manifold and the
bracket can be attached to the support bracket for the
upper intake manifold (large U-shaped bracket)
5) OBD1 throttle body is left alone
Transmission Preparation:
1) MK2 transmission can be used
a) MK2 clutch disk is required to mate to the transmission
shaft
b) MK2 8V or 16V setups can be used
c) MK3 pressure plate can be used with MK2 disk
2) MK3 transmission no modifications needed
3) MK3 starter can be used with MK2 or MK3 transmission
Modified by smokinjoe644 at 2:25 PM 2-7-2005