Converting a 1.4 petrol A2 to a 1.6 non FSI

Will try to figure out if the BCB ECU can be made to work with Lupo GTI injectors and throttle body.

Still not entirely sure what to do on the exhaust side, if the BBY with pre-cat is very restrictive or not. A cat in good working order is not a problem..

My initial thought would be yes, as long as its coded to the immobiliser.

Brett said that when doing the basic BCB swap, the removal of the cat internals made a big difference to the responsiveness of the engine.
 
Yeah, running no cat is not an option as it won't go through inspection, but it should be sufficient having the main cat. Then the cat-less exhaust manifold can be used. That said, a broken cat vs. no cat of course makes a big difference. In working order it should not do much harm.

Also need to have a look at fuel rails. The Bxx engines use a returnless fuel rail, and I am not sure if it will bolt up to the aluminum GTI intake, or if some custom brackets are needed.
 
Yeah, running no cat is not an option as it won't go through inspection, but it should be sufficient having the main cat. Then the cat-less exhaust manifold can be used. That said, a broken cat vs. no cat of course makes a big difference. In working order it should not do much harm.

Also need to have a look at fuel rails. The Bxx engines use a returnless fuel rail, and I am not sure if it will bolt up to the aluminum GTI intake, or if some custom brackets are needed.
I’m a little confused because the fuel rail on my car has a return feed for the fuel.
 
As far as I know, the return feed disappeared with the change to BBY. Coil on plug ignition and returnless fuel rail, as the regulator sits in the fuel filter and not on the rail.
 
Picked up a used BCB engine today, complete except exhaust manifold and wiring harness, which I anyway don't need.
I was looking at the throttle bodies of the engines and found the following info, did not do any measurements:

BBY (stock A2 1.4): 036 133 062 L (44 mm)
BCB (Golf 1.6 16V): 036 133 062 M (52 mm)
AVY (Lupo GTI): 036 133 062 J (?? mm)
 
Picked up a used BCB engine today, complete except exhaust manifold and wiring harness, which I anyway don't need.
I was looking at the throttle bodies of the engines and found the following info, did not do any measurements:

BBY (stock A2 1.4): 036 133 062 L (44 mm)
BCB (Golf 1.6 16V): 036 133 062 M (52 mm)
AVY (Lupo GTI): 036 133 062 J (?? mm)
Couldn’t resist going out to measure as I have a manifold on the shelf. It’s 60mm
 
Picked up a used BCB engine today, complete except exhaust manifold and wiring harness, which I anyway don't need.
I was looking at the throttle bodies of the engines and found the following info, did not do any measurements:

BBY (stock A2 1.4): 036 133 062 L (44 mm)
BCB (Golf 1.6 16V): 036 133 062 M (52 mm)
AVY (Lupo GTI): 036 133 062 J (?? mm)

Good luck with the project!
Ill be doing this early next year.
I have the manifolds already and i have a throttle body from a 1.6 megane which i believe fits.

Just writing my shopping list for it now
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Thanks!

I will also do this when I have the time - it will not be now during christmas! :)

My plan so far is as follows:

- BCB engine complete (OK, picked up yesterday, from a 2003 Golf)
- BCB ECU (ordered from a breaker, also from a 2003 Golf)
- Keeping the BCB oil cooler if physically possible (I think the BAD uses a similar setup, should be ok)
- To begin with, keeping the BCB intake manifold
- Lupo GTI throttle body, as the engine did not come with the stock BCB one (hope it will not throw codes, if so I will get a BCB one)
- BBY oil pan (I think the Golf oil pan does not fit the A2)
- BBY exhaust manifold as for now
- BBY "everything else that bolts to the engine"
- Painting the engine block, as it is cast iron, not aluminium like the BBY
- Making some adapter that looks stock to fit the stock air intake to the bigger throttle body
- Of course renewing the timing belt with everything around it before putting the engine in the car
- New clutch if the old one looks worn (will decide when I take it apart)

Not something that will snap your neck power-wise, but simple, stock-looking and will at least give the stock BCB performance, which should be noticeable, with 30 hp and almost 30 Nm more.
 
a thought,
if you extend the 5th gear on the BBY, the cruise control no longer works in the 5th.
If I now install a BCB ECU, it also expects a gear ratio as it is in the 1.6 16V Golf.
I suspect when installing the BCB ECU, the cruise control will no longer work.
 
  • Exhaust manifold (with pre-cat internal drilled out to release more power),

I plan to replace the AUA engine that recently froze to death with an AUS 1.6. Can you explain more about the exhaust manifold? Can I just swap it over to the AUS engine or do I have to modify it?
 
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