1.8t 20v swap
 

Best way for me to get this to the point I'm at is to copy form another forum. Please bare with me. I'll get there over the next few days.

Cheers John

I'll start by copying the first few posts from another forum to get us upto date.
I've decided that I'm going to do an engine swap in my track car project. More out of curiosity than anything.



I have no time limit on this, but will do my best not to let it drag on forever. Finishing off a xr2 turbo track car for a friend over the next week then this is top of the list. :wink:

Engine I will be using is the VAG 1.8 20v turbo, not my first choice of engine. Cheap & plenty available. Massive market for tuning & one of the main reasons was, easy to use standard ecu.

This is the RX8 I bought with low compression for £200
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Got the car dropped off to remove the engine from. Attachment 217696

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I'll do my best to answer any questions as I go. :wink:

Cheers John

Finally got the xr2 I was restoring & convering to a turbo finished & MOT'd last month.

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So after taking a few weeks off the REX has finally made it into the garage. :mrgreen:

Cheers John

Having dealt with the BS involved in keeping the 1.8T AEB engine happy in my 1999 Passat, I wish you the best of luck.

Removed the engine. Lots of seized & snapped bolts, as the car has been lying by the sea in Wick for 2 years before I bought her. #-o

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Now the hard work starts. Collect a loan of a mockup block later this week.

Cheers John

Well picked up a lone of a scrap block for mock up, so stuck it in to take a few measurements.
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Also got donated a few old flywheels & clutches to have a play with. Have found a mix that might work. 1.9 tdi a4 solid flywheel (if I can find one at a reasonable price) with a 4x4 Sierra Cosworth friction plate & Audi pressure plate. Fly would need a lip machined on it to take the rx8 starter ring gear. Or get a custom fly made to take rx8 clutch. Once adapter plate arrives I can take final measurements & make a decision.
So most of my time has been spent like this. :roll:
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Another 2 1/2 hours spent. Including picking up parts donated.

Cheers John

Broke out the CAD (cardboard aided design) to make a start on a mock up adapter plate. First plate will be made out of wood, just to check fitment & I can take all measurements from that. Saves money on wasted steal if it's not right. [-o<

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Cheers John

Offered the wooden mock up adapter up to the VW engine. So far so good. Just need to see if it fits both together. [-o<

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Cheers John

Engine & box bolted together using mock up adapter plate. Time to get engine mounts made, then make room for the head. #-o

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Cheers John

Spent some time, got the engine centred & at the proper hight in the bay. All measurements taken from gearbox on my rotary powered rx.
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Sat the head on to see how much I'll need to cut the bulkhead. :shock:
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Some more clearance required, could just use a bigger gearbox adapter, but want engine as far back as possible.
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Cheers John

Unfortunately I didn't manage to make the road trip this weekend. :roll: But did put some time to good use.

Dash looked so nice at the start of the day.
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But it had to go.
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Gave me the acess to cut the bulkhead so I could get the engine as far back as I want. Still lots of clearance needed & then work out how I get a heater back in her. :-k
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Cheers John

Most of the engine physical in the bay today. Lots had to come out the bulkhead. Need to put a bit of strength back into it next.
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Inlet on.
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Exhaust manifold on. This isn't the one I'll be using. Proper one I have has the turbo further forward.
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View from inside the car. Might not need fancy gauges. Passenger could just lean forward & feel intake & exhaust temps. :P
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Bonnet even fits. :D
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Cheers John

Didn't get a chance to work on the car today. But sat the strutbrace back on, just to show how far back the engine is sitting.
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Could even put the standard cover back on. :wink:
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Cheers John

Why did you choose this engine? I know it wasn't the first choice but whats the goal?

The goal is to have a cheap fun track car. Original plan was to build a Locost 7 style kit car. But when you pick up a 8 for £200, it's was a ready made rolling chassis. Engine it quite short & fits behind the subframe, cheap, readily available in Scotland & easy to tune. Not looking for big power. Around 300 to 350, will be fine.

Cheers John

Sorry guys not had much time to spend on the car. But managed to get some time during the week to make the adapter plate.
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Made the new bulkhead this weekend. Have left a removable inspection plate, to allow access to the rear of the engine.
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Should be enough room for the engine now.
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Plan of action for this week is to get engine back in with proper plate, make engine mounts & take final measurments for flywheel.

Hope to keep this post moving & updated now.

Will update time spent ASAP.

Cheers John

Passengers side engine mount tacked up.
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All welded up.
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Cheers John

Got the drivers side mount tacked up.
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All welded up.
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Mock up engine in, sitting on its own mounts. Still have proper spacers to make to replace washers.
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What do you think so far guys?

Cheers John

Made a start in the loom last night. Note to self, if someone who knows, tells you to try & avoid a loom from a Passat or A4. Next time listen. Most of loom is incased in a foam/tar, that has to be removed. #-o

Started like this
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Got it this far before I needed a break, it really is a nightmare. :(
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Everyone in work thinks I'm mad, sitting doing this on my teabreaks. :P

Cheers John

Well the plan for this week, while I'm waiting on parts. Is to get this cleaned up & ready to put in for the first of many times this weekend.
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Cheers John

Got the engine decluttered a bit for fitting in. Also cleaned up a bit too.
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Also cut down the front pulley & mounted the RX8 trigger wheel. This is needed to send a signal to the RX8 ECU & should make the Rev counter, power steering & ABS work. ;)
Original pulley
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Cut aircon belt drive off
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Got a stroke of luck to centre it. When I put bolts through the original mounting holes, they are a tight fit into the centre of the VW pulley. There for centering the trigger wheel. :thumbup:
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All done.
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Cheers John

Love it when I get to play with big boy toys. Got the plasma cutter out to make stronger plates for the engine mounts. Using what's left of the steel from the adapter plate.
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Should be strong enough this time. 10mm steel. Will update times & costs tonight.

Cheers John

Re did the engine mounts.

First go just didn't look strong enough
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Looks a bit better now.
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Also fitted the RX8 alternator to the Audi engine bracket. Using the RX8 starter & charging loom.
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Cheers John

Car looks like it's went backwards this weekend. But got engine bang centre in the bay & holes drilled in subframe for the engine mounts.

Before removing the mockup engine hopefully for the last time.
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Bay looks very empty now. Also cut out the support for the battery, I'll make a new one as coolant pipe has to change direction & be mounted higher.
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Oil coolers & pipework also removed, for the moment anyway.

Cheers John