2g head on a 90 tsi swap

[racersedge1821]

k guys i got a 1990 tsi with a bad head and piston just ordered a 2 g rebuild kit(2g pistons on 1g rods hope works out well) my question is can i just swap over my 2g head and intake after i port the oil mod #1 and bore the head bolts out with a 1/2 inch. bit will my CAS and fuel rail bolt right up or do i use the 2g fuel rail?also i'm using my 90 tb on the second gen intake heard it will be an upgrade just asking for swap info all i see is 2g heads on a 6bolt forums but they are swapped into a second gen car ty again guys need replies asap bout to start building.

 

[kbiker76]

http://www.dsmtuners.com/forums/articles-engine-fuel/152329-how-do-6-bolt-swap-what-you-need.html

That link has tons of information about a 6 bolt swap

 

[racersedge1821]

ty very much for the quick responce although it was for a 6 bolt to a 2g i've been reading this also but i need the swap info for a 1g car with a 2g head ty

 

[hubz91talontsi]

The fuel rail will bolt to the intake manifold. Only difference is the way the fuel lines connect to the rail. Which in your case doesn't matter. Get a 91-94 Throttle body. 90's use different parts that are hard to find. So you're running a 2g head off a 95-96? Im not sure about that part, because i have a 99 head. Maybe someone else can help you with that bit. Also i didn't have to bore the head to fit the head studs.. Im not sure why - I don't know if anyone else has gotten away with that either.

 

[rick_dsm90]

God i hope this doesnt turn into a 1g-2g head debate

we did this to a friends car a few years ago

as long as you use the intake it will fit and bore the head bolt holes out from 11mm to 12mm. the 1g cas should fit the 2g head but i cant remember if the 1g rail fit or not. if you use the 90tb youll have to make your own fiav block off plat. (i have a 90 aswell)

on a side note try and find an EVO3 intake with the small ports. EGR comes blocked and it makes more power then the stock 2g.

 

[hubz91talontsi]

Time out. I said that the rail bolts up different -- which WOULD matter. The difference if i can remember correctly is the way the fuel line bolts to the rail. You may have to get some AN fittings that bolt in. Then run a AN line from your filter to the rail. I could be wrong -- not 100% sure.

 

[racersedge1821]

sweet ty so much guys also using the 1g cams in my 2g head heard this is an upgrade plan on seperating the 2g intake from the 2g head and port matching and polishing it up before i install it onto the block and plan on porting the turbo housing as well looking forward to the build i bought a 2g rebuild kit hope all is well with that i read a sec ago that i will have to machine the top ends of the rod to mate up the new 2g pistons i got coming wich is no biggyty guys for everything i'll keep u guys posted on the build my main concern is the timing shit of these engines was thinking of doing a balance shaft removal also but funds are getting skimp (wife regulated funds)

 

[Cory-CR]

Currently have a 2G head on my '91. All of the 1G parts like manifolds, fuel rail, etc bolted up perfectly no problems at all. The problem I DID run into was that I was using ARP head studs, for a 6-bolt. I learned after trying to set the 2G head over the studs that it didn't fit, they are different sizes. The 6-Bolt heads have 12mm holes for the head bolts to go through, where the 7-Bolt heads have 11mm holes. I opted to have the extra 1mm milled out of the 2G head, slid right on and has been running without any problems.

I am not sure if factory 1G head bolts will go through the 2G head or not, but I threw those to the curb long ago. Nothing that couldn't be resolved, but that is a potential issue you might face.

Also I just saw you bought a rebuild kit for a 2G, which I assume includes full engine gasket set. Not all of these gaskets are going to fit if you are using a 6-Bolt block. Many will be different.

 

[FLASH1970]

Currently have a 2G head on my '91. All of the 1G parts like manifolds, fuel rail, etc bolted up perfectly no problems at all.

I'd swap the manifolds to 2g if you can... The intake ports are different on a 2g head and you're robbing your car of power by having a 1g intake manifold on a 2g head. And the 2g exhaust manifold is a better design than the 1g ones and less likely to crack...

To the OP, I know the 95-96 cars had the CAS on the driver's side of the engine under the cam sprocket. Not sure if that matters when using a 1g cas. That's the only thing I can think of. Just drill out the holes to accept the bigger 1g bolts/ studs, do the oil port mods, and the fuel line issues that have already been mentioned.

 

[racersedge1821]

u guys have any idea like what gaskets will be different when i use the 2g rebuild kit cause if i get an idea i'll go ahead and buy what i'll be missing

 

[Cory-CR]

I'd swap the manifolds to 2g if you can... The intake ports are different on a 2g head and you're robbing your car of power by having a 1g intake manifold on a 2g head. And the 2g exhaust manifold is a better design than the 1g ones and less likely to crack...

Using a tubular exhaust manifold on my setup. Yeah the 2g intake manifold would be a bit better than the 1g but I'm working on a setup for a Cyclone manifold and I will have the head port matched to that manifold.

As for which gaskets will be different, pretty much anything on the block. So rear main, front case, oil filter housing, probably oil pan and water pump, a number of things.

 

[racersedge1821]

i'm gonna run the 2g head and intake just gonna gasket match the intake to the head and ###### smooth up and gasket match the 2g exaust mani to head. well looks like i'll have a shit ton of gaskets to be selling for a 2g anyone need them

 

[Dsm4lyfe12]

i wiseman told me that the head bolts are EXACTLY the same.

 

[95weclipse]

No Dan the 6 bolt head bolts are 12mm and the 7 bolt head bolts are 11mm. I hope you got a 6 bolt oil pump because the 7 bolt oil pump DOES NOT fit the 6 bolt the bolt block. Unless you drill it out and tap and fill in the right spots then it will fit. You can use the 6 bolt water tube and thermostat housing the 7 bolt head has the bolt holes for it.

 

[Cory-CR]

i wiseman told me that the head bolts are EXACTLY the same.

Not the same, I promise. One went slightly into the head and almost got stuck when I figured this out the hard way.

 

[racersedge1821]

so pretty much looks like if i can i need to just send the kit i bought back cause the pistons are higher compression as well 8.5.1 i believe so i hope they take it back when i get it here haven't recieved it yet

u wouldn't happen to know exactly what holes i'll have to modify to make the 7bolt oil pump work with the 6bolt block?

 

[racersedge1821]

guys i got my old head and timing belt off my car and was looking for the balance shaft belt and tensioner guess what i don't have balance shafts even in this 90 what coulda happened could it already been eliminated or is this a 7 bolt in my 90 ty