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VW ABA 2.0 stroker motor build


This is an engine build for a local customer. He is a VW fanatic and likes doing things just a little different than most. After collecting parts for the last 8 years he finally decided to go ahead with this engine build. The goal is a reliable, torquy, naturally aspirated engine to power a 1989 VW Cabrio. This engine will use an 8 valve SOHC cylinder head and an OBD2 conversion.


  • JE SRP Autotech 83.5mm forged piston kit with piston pins, lock, and rings
  • Cunningham I-beam forged steel connecting rods
  • VW TDI diesel 95.5mm stroke crankshaft
  • Audi 80 2.o liter block with piston oil cooling jets
  • New Bosch distributor
  • Blueprinted oil pump
  • OEM main and rod bearings
  • ARP main stud kit
  • ARP head stud kit
  • Dual valve springs
  • Titanium retainers
  • 268 degree camshaft
  • OEM metal head gasket
  • OEM oil baffle shield
  • New OEM oil pan
  • All new seals and gaskets
  • Bore/hone block to size
  • Deck mill block and hand stone to prepare for metal head gasket
  • Weight match connecting rods
  • Measure connecting rod bolt length and record on log book
  • Weight match pistons
  • Check main and rod bearing clearances using micrometers and bore gauges
  • Check piston to cylinder clearance using micrometers and bore gauges
  • Balance and micropolish crankshaft
  • Install Mallory heavy metal into crankshaft for balancing
  • Measure piston dish and combustion volume and calculate compression ratio
  • Disassemble, clean, and inspect oil pump
  • File piston ring gap to size using Childs & Albert piston ring grinder
Pictures of the engine build in progress:


12 thoughts on “VW ABA 2.0 stroker motor build

  1. I have a 97 ABA 2.0 block. With this 95.5mm stroker diesel what exact size rods and pistons do I use for a turbo motor

  2. Hello Brian,
    This motor received custom length connecting rods and custom compression height pistons. I can design and supply you both items. Typical cost of custom made pistons is $750, including coatings, and $1200-1300 for a set of connecting rods, depending on rod bolt options. I will need additional information about your motor and in which type of motorsports you will be participating. You may email me with additional questions: [email protected]
    Thank you!

  3. What does the hole conversion cost

  4. Hello Louis,
    Engine preparation cost can vary greatly based on condition of your engine and specifications you require(ie street, drag racing, road course racing). I will email you for additional details and we can discuss your project.

  5. hey ran across your site looking for information on how to build power for a 2.0l vw gas engine. So i was wondering if could point me in the right direction. I have a 1999 vw bettle 2.0l aeg.Had the car for years now! and plan on rebuild but needed help with ideas to get stared this summer.whats the best route want the engine to last.n/a if possible.

  6. Hello Carl,
    Please check your email for additional information request.

  7. Hi

    I am interested in these builds. Got a 2001 jetta 2.0 5

  8. Hello Michael,
    Due to current workload, we are not offering engine preparation services until October 2017. If that is an acceptable timeframe, we can discuss additional details and a budget for your project.

  9. Hi Pavel ! I’ve been in love with my ’84 rabbit GTI since I bought it in the eighties. I’ve heard about oversize rebuilds for a 2.0 16v – 2.2 or 2.3 L. Is this possible & what is the approximate cost range ? Thx.

  10. Hello Phil,
    The beauty of VW/Audi engines is how modular most engine components are and the numerous block, crank, cylinder head, and engine displacement combinations that can be achieved by mixing and matching parts. Your 1.8L engine can be bored out to make a 1.9L engine. Huge overbore on the 1.8L block is possible, and when matched with the 1.8L crankshaft, gives 1961cc, roughly 2.0L engine. A longer stroke crankshaft from a 2.0L engine is required if you want a 2.0L engine without going to extreme overbore. You can also make a stroker engine by using the diesel/TDI crankshaft. A reasonable overbore with a diesel crank provides a 2.1L engine. Diesel crank with an aggressive overbore provides almost 2.2L engine. Standard forged connecting rods available on the market will work with all these combinations. High-performance rod and main bearings are readily available as well. Forged pistons will have to be a custom design to suit the correct crankshaft, cylinder head, and achieve target compression ratio.

    A price is hard to estimate since there are a lot of variables that cannot be accounted for until your engine is disassembled and inspected. Typically, a block rebuild with forged pistons, forged rods, bearings, ARP fasteners, and necessary machine work starts at $3500.

  11. Hi, I have a 97 Jetta GT, 2.0 ABA, looking to increase the torque and hp. Have read your above info and you mention the TDI 95.5 mm stroke crankshaft, are these not counter weighted from the factory. Which TDI have that crank? How do you come up with the connecting rods for any engine. Thanks Mike.

  12. Hello Mike,
    All VW diesel, 95.5mm stroke, crankshafts are fully counterweighted. It is a standard item in all TDI engines that are timing belt driven. The Mk3 Golf/Jetta 1.9TDI crankshaft is a direct swap. You can also use the later 1.9TDI crankshaft but it will require crankshaft modification and shortening of the snout. Either the connecting rods or the pistons have to be custom made to accommodate the longer stroke. Typically, a standard ABA connecting rod length, which is 159mm, can be retained and a custom forged piston made with a shorter compression height. A custom piston is a much more cost-effective solution to building a stroker ABA than a custom short rod. The compression height has to be reduced about 1.35mm(.053in); final piston design will have the appropriate specs based on your exact block height, target piston-to-head clearance, and other vital information.

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