There's a fair few threads on 1.8T conversions........in fact there are oodles of 'em.....so lets just say i'm a little confused dot com. Technically, I can spanner, paint, weld, and am a wire-head at heart so have no apprehension about doing this. Being equipped with a fair few years of wasting time, leads me to strive to do this job once without excessive trial and error. I've just completed the engine conversion of my Mk2 using a 2L TSR engine, enhanced gearbox with quaife LSD....and it's great, but i've always had plans for a 20V after this. I bought a wrecked TT with low miles on a BAM engine with a remapped ECU. This is waiting for me to use, however i've got a few aspects of the install to iron out in my own mind first - and am looking for some help & advice please? Engine - BAM 20v 1.8T all stock including intake and turbo Flywheel - Currently stock - If mating to an 02R, I guess providing the input spline matches existing clutch, we're good to go? Throttle Body - I have DBW at present - Is there a good reason to steer away from DBW? - Is DBW compatible with aftermarket ECU? - Passat or VR6 cable throttle alternative? - Are these compatible with existing ECU and aftermarket? ECU - I have the existing ECU which has been remapped apparently - I have keys, clocks, looms, and could get the ECU immobiliser bypassed easily Do I go stock ECU or aftermarket? MBE ecus from QPENG seem to be popular. Can I get rid of VVT control and Aux air pump in either scenario? What about Lambda probe - do i still need this without Cat? Exhaust - Presume something like QPENG downpipe is the weapon of choice? - Any others available? - Decat of course? - Will the downpipe bolt straight onto a silencer system? - Currently I have a 50mm s/s Jetex system - too small? - Will I need 2.5" ? Engine Mounts - Rear I currently have a vibratechnics which I assume will work? - Just bolt 8v bracket to 20v lump? - Front i have a mount off a previous shell which had a 20V BAM previously (looks nothing like a stock mount) - Again - just use stock bracket off 8v? - Gearbox mount ?? Gearbox - I have an 02R from a Polo Gti which i'm gonna use for now - Hydraulic clutch so presume i'll need a passat cluch M/C and a reservoir with tapoff? Brakes - Already upgraded fronts to 288x22mm from a G60 / Mk3 early Gti - Still running 4x100 hubs - Rears are new stock 8v calipers and solid discs - Bias valve is stock 8v - Master cylinder is 23mm off a Mk3 Tdi (I have the reservoir still with the clutch tapping) Presume this will all be sufficient for now? - Will I need a different M/C due to clearance issues? Intercooler - Not thought about this much yet. - Possibly sprinter FMIC? Radiator - I have a new all-Ali hiflow rad for a Mk2 16V or a used VR6 Mk3 - I guess either would suffice for road use? - I have a slim pacet fan currently fitted to existign 8V rad I can reuse. Power Steering - Not required, so presumably ditch this and use a shorter alternator belt? - Focus belt the one to use? which model? Fuelling - I've read that 16v Mk2 fuel pump would suffice? - Or go for Vr6 Mk3 pump and complete tank? - Any issues with existing fuel gauge if using Mk3 sender? Is this a worthwhile conversion? any benefits like pump in tank? Gauges - For the stock gauges I guess the coil signal wont drive the tacho? - For speedo, whats the best way forward? - I'm currently developing LCD clocks/gauge conversion with a guru friend of mine..watch this space. (a good reason to keep stock ECU so that all data can be streamed over OBD to the instrument binnacle) I probably forgot something......but that's a good start!
you can use th mk2 clocks, ignition, key etc if you speak to andyout on here and he can help you. If you search on here there is a thread in which Mook gives a part number for a halfords belt that fits without powersteering. I have heard the mk2 16v lift and undercar pump will be fine if they are newly replaced but a mk3 tank with vr6 pump might be best for re-mapped BAM power, will fit with mk2 tank brackets and mk3 lines. fit a rado / passat hydro pedal box
This might help: http://www.clubgti.com/forum/showthread.php?t=200467 i started it ages ago when i started mine. (still havent really even started ) also i have started numerous threads including one about fuel pump rates which help you answer your question. good look
There is so much to consider when doing a 1.8T conversion. Im still undecided on a few things but with the help on here im sure everything will fall into place for the likes of us
flywheel if its a Dual mass thingy then you might want to bin in favour of solid 228mm unit from 02a mk2/3/corrado/passat. use a vr6 clutch kit throttle body no reason to stay away from dbw, ony thing is you have to mount the pedal. its not hard done on here a few times. just a case of mkaing up an l bracket im sure i saw someone made one up which just bolts on no weldding if you go aftermarket most of these will be dbc, in this case abf tb is the one which fits after some slight fettling. was a post on here recent. wont work on bam ecu obv as it expects dbw type ecu stock ecu is easier, plug in and go. aftermarket will need tuning by someone who knows what they are doing, no plug n play solution unfortunatly still need a lambda probe for best performance. if it has 2 lambdas can get 2nd one coded out plus any of the other bits you fancy deleting. most/all aftermarket ecus will take a signal from a wideband controller, wont have vvt control and the like either billy basic engine mounts if using an 02x type box you need a corrado/passat front and rear bracket as the engine position isnt quite the same as with 020. see note in braking system re rear mount. box mount if the one you have is mk4 you need the bracket off a mk2/3/corrado with 02a gearbox 02r is that basically an 02a style box? hydro clutch use corrado/passat pedal box with bulkhead beaten flat and hole drilled, or fit seat abf/tdi cable conversion kit brakes fit seat 1.8t master cylinder for clearance, can also get this from ford focus. look at sc0rians 1.8t rallye build thread its all in there. other option if you keep oem 22mm is to use a specific passat rear mount that shoves engine forward a bit more fuelling: either mk2 8v/16v k-jet pump, or mk1 pump + mk3 carrier and mk1./mk3 polo reservoir as per sc0rtians build thread, whatever falls into your lap. could also use mk3 fuel tank, lines and filter carrier setup with mk3 gti/16v/vr6 pump. mk3 tank has benefit of pump being nice and safe inside tank so no corrosion, plus way easier to find in scrappy gauges if use mk2 clocks need an adaptor, is a thread on here somewhere believe started by sc0rian. speedo if box has a sensor hole then can use mk2 1.3 cable on the back of 02a sender, the one thats in the box now might work you unscrew electric bit off back and 1.3 screws on. if going aftermarket then see if it can take an oem mk3/4 electronic speedo signal
I have done a mk2 BAM conversion , if you get stuck on anything let me know , i used a J plate Base 16v I used - BAM and Passat 02A AGC box , Quaife 6speed gearkit and Diff - used factory power steering pump from the mk2 , really like it - Hotgolf flywheel and Vr6 clutch kit - Motec ECU and loom made by another company , using Mk3 Vr6 Throttle body VVT control is connected up and used in the map Aux air pump - not used Lambda - not used , can be configured all it will give is better mpg when driving a a nice constant speed - Hydraulic clutch setup using Corrado & passat parts ( you need heat shields around it all, turbo is close to the clutch line ) - Vibratechnics mounts and solid front mount , using Passat rear engine bracket Problems here http://www.clubgti.com/forum/showthread.php?p=2035347 - Golf Rallye intercooler , with the end drivers side end cut and moved to a different angle ( bit expensive to mod but i do like the factory fit , so balls to it , intake temps are ok ) - Gold Rallye rad ( non genuine ) , bolts to the rallye intercooler - 16v Kjet fuel system no mods - Rev counter I used a 034EFI tach adaptor for adapting older "High Voltage" tachometers to a low current tach output of the 034EFI ECU. i did try resistors and and a load of other methods that , none worked, this box worked a treat , i reckon there is a mini coil on there You have not asked about the water temperature sender , now you can use the green 4 pin with a resitor , but i was not trusting that as i am sure the guage values at the extends would be incorrect , so i used a adaptor in the water line about 1" from the green sender using the mk2 valver sender , only problem is that this means its not in the flow of the water when on warm up so will under read the water temp value a bit , but is correct when the thermostat opens
thing with the sensor is confusing! some have said they had to use a resistor, but when i did this on one of my looms the guy found it didnt work at all so binned the resistor and it worked fine without! i have read that the new sensors work direct with mk1/2/3 dash gauges? dunno really as i just make the looms i havent actually done a MK4 conversion myself
THanks for all your combined insight so far.......very helpful. As for the water temp sender - yes I didn't list this.....will consider that - presumably to drive the Mk2 dash gauge? So, does the ECU (of whatever flavour) use a separate water temp sender for enrichment / cold start? If so, is it the original 1.8T sender? 4-pin?
mk4 ecu uses the 4 pin sender, its actually 2 separate sensors in 1. 1 side does dash, other side does ecu aftermarket can use pretty much any sender you like, they normally have the option to code in the values. if going aftermarket what i do is use a mk3 golf 8v 4 pin ecu/dash sender. that way you know the dash part of it will definitely run your mk2 clocks, and you can setup the ecu to work with the ecu part resistance values
Yes buddy, I at least knew that bit lol Aah ok cool, I have a Mk3 sensor off an AHU '95 TDi 90hp I "threw" in my T4. Here
O2J 'box. Code JDB. Ratios aren't bad - i've done my sums! Cable shift. Digital speedo signal. Hydraulic clutch slave cyl.
Do BAM engines vary between the TT and the S3 ? I have a 64k out the TT donor...... And I just bought this S3 with 83k on it, in case I need another......
ROFL.......dont think so......4WD maybe ! lol........but that's alotta work. Throttle Body Mk3 VR6 - is that OBD 1 ?? MBE ECU The BAM has 4-pin coil packs ie amplified. Will an MBE ECU which expects 3-pin packs, still work (if I get 12v to the packs for power)? or would I be best to get the 3-pin packs? Are they interchangable? Which packs are "best" for the BAM ?
LOL - really, I'm not fitting two engines.....no, seriously! I'll sell one of the BAMs sooner or later.
