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

Modified flywheel turned up today, so I'll need to get it all cleaned up & fitted to proper engine.
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Hope to have a go at fitting engine this weekend now. Possibly firing it soon. WISH ME LUCK


Cheers John

The proper engine has made it into the garage now. Flywheel & clutch fitted, almost ready for the big lift tomorrow.
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Cheers John

Engine is finally in. What a nightmare that turned out to be. :( Had never put the engine in complete before & had never put sump on mockup engine. What a mistake that was. :cry: Lots of small jobs done I wasn't looking forward to due to my error. Subframe bolts freed off, steering rack bolts freed off & anti-roll bar freed off.
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Had to make a small bit of clearance on the subframe for the sump, but just glad to see it in.
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Now the fun starts, wiring & piping it up next.

Will need to update times. Have them all wrote down in the garage.

Cheers John

Started to get some of the pipe work sorted. I thought I start with the metal pipes on the engine. Started with the Passat top pipe.
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Was going to interfere with the manifold I'm using.
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With a simple bit of cutting & welding, it's sorted. I hope.
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I've also made to bottom pipe fit my application, but forgot to take pics.

Times also updated on the first page.

Cheers John

A few small jobs done today.

Blanking plate fitted to the rear of the head.
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Wiring all connected to the engine, think I'll be able to fit it nice & tidy with minimum work.
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Piped most of the turbo up temporarily, with the pipes I have about. Just so I can try & test fire it before going any further.
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Plan is to pipe up the rest of the intake side of things, try & test fire it for next weekend if I get time & get ECU back. Getting a bit nervous now.

Cheers John

Not had much time to work on the car the last couple of weeks. Been busy getting the retired track car out of hibernation & ready for a rolling road day. Back on it over the next week.

The car the rx8 is replacing on track.

Cheers John

Fitted the starter today & checked that it would still engage with the modified flywheel. Was chuffed to hear it turn over.


Cheers John

Unfortunately not really much to report at the moment. I'm still waiting on my ECU coming back. :-k

Just thought I'd post to let you's know the project is still ongoing.

Have spent some of my time helping some friends compete at knockhill. Which lets me play with some interesting cars.
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Also a few mods to the fiesta that we built last year. Arches rolled to get bigger wheels on to allow for a brake conversion
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Did get a couple of jobs done to the rx8. Drilled & tapped the rear of the head to take an outlet that suits my application.
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Messed about with the water pipes a bit till I was totally happy with them. Will update times ASAP.

Almost forgot, got some tail pipes FOC for me to start making the exhaust. Should be big enough. :lol:
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Cheers John

ECU finally back & we have a spark.


Cheers John

Added some fuel to the spark yesterday & she fired up. 8)


Cheers John

Turbo coolant feed pipe made.
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Bottom radiator pipe made.
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Top radiator pipe made.
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Cheers John

Been a while since I've been able to work on the car. But finally got the intercooler in a position I'm happy with. Had to remove the front crash bar, I'll make a different one up. Didn't realise the intercooler was this big.
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Cheers John

Started to mock up the boost pipes. Even made my own bead roller of sorts. Should do the job.
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First boost pipe just about mocked up.
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Cheers John

Got one of the boost pipes done. Quite happy with it for a first attempt. :)
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Have to make an exhaust manifold now. Lesson learned about buying a cheap eBay one.
:oops: #-o

Cheers John

New Exhaust manifold here. Some assembly required.
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Could be a while before it gets done. :cry:
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Find out on Thursday if it's broken or not.

Cheers John

Started to mess about & mock up the exhaust manifold tonight. No off the shelf manifold will fit, due to how far I'm into the bulkhead. #-o
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I'll need to sit & update first post with times, still start the stopwatch when I go into the garage. Just keep forgetting to lift notepad to update the time & don't want to guess at it, or lie about time. :^o

Cheers John

Thankfully the ankle is all healed up now & I can finally get on with the car. I've not been sitting about doing nothing though.

Last month I got the chance of being part of the pit crew for a super tourer at the super tourers race at knockhill & also part of the crew for the ultima again. To say I was chuffed is an understatement, even although I was still hobbling about.
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Unfortunately one of the BMW cup cars I help with had a small bump & any spare time has been spent repairing that. But worth it finished today & back ready to race this weekend.

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This is the last race of the year, so more time to get the RX8 done.



Cheers John

Managed to get a few bits done. Brackets made for the breather & ABS block. Both fitted. Just waiting on 2 ends to finish the breather pipes. But I'll get the brake pipes done while I wait.

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Cheers John

Been a bit distracted from the project again, missed track too much. So dragged the 3 door out & got it ready for a bit of a play last weekend the weekend

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Finally got the manifold made up, let's hope it works. On to making the intake pipe & boost pipe up. Ends for breathers here too, so let's hope for big progress this week.

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That's us just about up to date.

Cheers john

Any pics looking up from the bottom of the car? Curious as to the oil pan ground clearance!

Did you decide to fit the engine that far back into the bay, in the name of using the stock trans? Progress looks awesome :)

Will get some pics for you when I get home from work. It was a combination of 2 things to put engine as far back. Yes one was to match up with stock drivetrain, the other was to try & keep the weight as close to the stock rotory as possible.

Cheers John

Forgot I had an engine mounting off measuring for spacers. Will get that on & get the pics for you ASAP.

Sorry updates have been so slow guys, just can't get a minute to work on the car just now.

Managed to make a boss & mount the map sensor. Not much,but at least it's a job off the list.
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Cheers John

Hope these pics help you.

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Sump sits at it lowest point about level with the subframe. Oil level sensor will be removed & replaced with a flat plate. This is with the rx8 gearbox at the night it would be at attached to the rotary.

Hope this helps. If you'd like more pics just let me know.

Cheers John

Got some time at last to start mocking up the turbo side boost pipe.
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Not to sure about it at the moment, would like the turbo outlet a bit shorter.

Cheers John