Mk1 VW Golf 1.8T 20V - VEMS - K04 Turbo

[mk1classic]

Time to write a few words about my long time project on this forum.

I started back in '99 when I bought a set of "new" used wheels (as seen below). I had to look for a new project car to modify. A year later the car was in the garage but due to studies in UK and Norway the project was halted for some time. As time went by the plans for an engine conversion grew. First plan was to Megasquirt the original 1.8L 8V GTI engine, then changed to a 1.8L 16V on throttlebodies but as time went past I can across a 1.8T 20V from an Audi A4 (engine code: AEB) with a broken cam belt.

The engine was rebuilt with a "larger" K04 turbo from the TT 225hp engines. Now fitted with a VEMS V3.3 and 4x 440cc/min Bosch (Ford) injectors and OEM COPs. Original engine triggers have been used, 60-2 wheel on the crank with inductive sensor and a single window trigger with hall sensor on the camshaft. Fuel is delivered by a Bosch 044 fuel pump instead of the original old and worn out fuel pump. Gearbox has been changed to a 02A from a VW Corrado G60 with a torque sensing diff. Brakes are updated to 256mm front (similar to a Scirocco II 16V) and mk2 GTI rear.

All wiring was done by me (actually all work except for the final paint outside the car was done by me)

4x20 digit display is installed inside the car (See pic below)

This is how it all started:

The day I got it home (been a unfinished project for a few people before I got it)


Engine ready:


Engine in the car and the wiring for just the engine hanging out:


All in place (more or less):


4x20 display installed in the console:


On the road for the first time:


After the first drive the car was sent to winter storage. As soon as the snow and ice goes away the car will be back on the road for some tuning. Until now it's been untuned and hard to get started.

Link to WIKI Page
Link to pictures of the build

[dnb]

Great install job.  I've always liked these cars since I passed my test. :)

[BenFenner]

I remember seeing your car on the wiki. It really stood out to me. Excellent work!

[mk1classic]

Ups... The engine dropped an exhaust valve and the valve stem broke.

[Denmark]

Look on the bright side, you had been thinking about upgrading the internals any way :)



/Skassa

[jadzwin]

It is common problem wit 20V heads :( You should better put 16V head with bigger valves.

Cheers
Jadzwin

[GTOBB]

or change all valvetrain to better one :) , we got the same problem 2 month ago