installing mk4 AGU engine / 02J gearbox

[TomBob]

Hey all,

I'm moving on my long-stalled mk1 golf 4-door project - engine and gearbox upgrade to mk4 GTI ... the kitchen can wait.
I have a stock donor mk4 gti complete and am looking at what I will take. It has a K03 turbo but I'm thinking K04 - I read the AGU engine has forged crank, rods and pistons so can take up to 300HP with just turbo and injectors.

The mk1 is at the shop having the dings and rust removed but they will need the engine/gearbox mounts soon so the engine bay can be finished. I'm thinking of using the mk4 gear change mount (... possibly the Recaro seats but I can decide on that later).
I've looked at a number of UK forum postings to see what others have done. It seems these were all done years ago so I'm late to the party.

I've also looked at commercially available mounts, downpipe, adapters, etc from sites like Classic-vw are specialists in the mk1 golf models, including scirocco, jetta and caddy. We are also your No1 choice for the hard to find and obsolete parts.. Nothing is cheap but freight just pushes it over the top. Am I missing something? Does anyone import from UK (or where ever), onto which I can add my things?
Anyone going to tell me to do the kitchen first?

Tom.

[h100vw]

Tom, we have done a couple of 1.8T swaps at TTY Euro. Just about to do a MK2 GTI swap in the next month or so.
You want Epytec mounts. Dont get all excited about turbos. The 2 we have have K03s's and ME7 ecus, making around 200hp. You dont really need more.

And if you do want a bigger turbo, get the tuner organised first!! It will need the right fuel pump, as well as injectors and MAF. Intercooling on a MK1 needs thought as they dont have a great deal of room up front.
All 1.8ts will handle 300hp on stock rods. I have built up a couple of Polos that made 200kw at the wheels on a stock engine.

[TomBob]

Thanks Dub Crazy.

It's early days so I appreciate any advice!
There are so many options and everything is expensive after converting to AUD.

I was thinking the Epytec mounts but got stuck at the downpipes - the K03 and K04 pipes are different so I thought I might regret buying the smaller pipe if I later decided on the K04 turbo, which requires the larger pipe. I'm probably overthinking this and will keep the K03.

Classic suggest the Mercedes Sprinter intercooler: Mercedes Sprinter Intercooler Mk1 Golf Turbo Conversion. I guess I can find one of these at a wreckers.

Choosing an ECU seem to be like choosing a religion where adherents to other religions must be put to death. Should I find the tuner first and accept their ECU advice?

There are all sorts of MK1 reinforcing gusset and brace comments on some forums. I want the car to look standard but handling is a safety issue with 200-300HP so stiffening and bracing is not unreasonable.

Any advice on braces and gussets before the panel beater gets to the finishing work?
I'm in inner west Sydney - any tuner recommendations?

Cheers,
Tom.

[h100vw]

I can defeat the immobiliser in ME3.8 or ME7 to allow you to run the engine, AGU or later 1.8T. We have 2 MK1s converted in the workshop. They have no additional welded in strengthening. Both do run upper and lower strut braces though.

I am sure you will find a K03/s plenty fast enough with a tune. Dont make life hard by spending money on a K04-023. 200hp is mad in a MK1.

I have a 200kw atw Polo GTI, you dont want that in a MK1, it will pull it apart.

Gavin

[Sharkie]

200hp is mad in a MK1.

I have a 200kw atw Polo GTI, you dont want that in a MK1, it will pull it apart.

Gavin

Mmmm, I do and don't agree at the same time Gavin ... had 243kw atw in a Mk1, it was a crazy drive, (the don't) trying to kill you everytime you put your foot down but, (the do) was also crazy fast.





It was NOT suitable as a daily by any stretch of the imagination. Would I do it again, probably

[h100vw]

Haha, as a road car unless conditions are perfect, my Polo is compromised by grip. The L280 ones I have put together for customers, drive way better on the street.
The 2 1.8t MK1s we have here are ballistic, the hardtop has broken driveshafts on a stock turbo/stage 2 tune. The cabby needs driving with care to keep traction, it would be tiring to drive all the time.

I wouldn't make one for myself with anything bigger than an L280. Softer delivery than the spiky K03s. That would probably be the best compromise.

[TomBob]

Thanks guys. This is really good feedback and made me think more constructively.
(Gavin, I'll talk with you commercially about the ECU when I'm closer to that part of the build and I will retain the K03 ... for now. Thanks for the feedback)

I asked Epytec about the full kit installation listed on their site. It includes "accelerator pedal adapter to electronic accelerator cable" ... but that doesn't seem to apply for the cable throttled AGU.

Epytec replied this kit isn't suitable for RHD cars (which I thought odd) and suggested I purchase just the engine and GB mounts.

I was thinking of their hydraulic clutch as I've pulled a few clutch cables through firewalls over the years and cable operation in these cars has always felt a bit iffy if the cable is more than 2 weeks old. Has anyone installed the hydraulic kit?

Lastly, I was thinking of their reinforcing plate for the front-end.

The shopping list is getting long but this thing has sat in my garage for 12 years and I'm pushing 60 so it's now or never!

Cheers,
Tom.

[h100vw]

AGU has a throttle cable, not sure what cable you use for that. Definitely convert to hydraulic clutch though.

The 2 we have here are electronic pedals.

[TomBob]

Been while but back on it.

DubCrazy, I've extracted the ECU so I'll PM or call you direct about the Immo.

"AGU has a throttle cable, not sure what cable you use for that"
My research is P/N 192-721-555 (for MK2). The ends look right but not sure about length (or routing). Might need to buy one to find out.

"Definitely convert to hydraulic clutch though"
Advice accepted. I was going to order the Epytec mounts from Retrofication.co.uk but their hydraulic clutch doesn't seem to be Epytec (or at least the kit looks different). Does it matter? It might depend on the gearbox choice (below).

On the turbo: "Softer delivery than the spiky K03s"
Super interested to read about the L280 (L280 1.8T – Littco). I want the car to look original, NOT be noisy and drive so well my wife can take it to the shops (well, maybe ...). Torque is more important than power and I'd like smooth delivery.

Any advice on downpipes? If I stick with the K03 and later upgrade to L280, will that be a different downpipe or a straight swap? For that matter, where do I buy the downpipe (I imagine import)?

I've not read the codes on the current 020 5-speed, but I speculate it's from a diesel - I think 100kph is about 2300rpm in 5th. I'd prefer a low ratio for calmer driving, but I guess the donor 02J will be a higher ratio because the wheel size difference. Any thoughts on keeping the 020 until it blows up? Were there any low ratio 02Js delivered to Aus? What transmission do others use?

Looking at a ECU -> analogue converter for the tacho. Is this what people do?
1.8t Rev Counter Conversion box



– Dreadnought Customs Limited

Lots of questions but the plan is firming.
Thanks folks.

[TomBob]

Been stalled while in Melbourne but back in Sydney for a bit so up for another push.

Thanks Gavin for the immo defeat!

I've ordered the Epytec mounts and a hydraulic clutch kit from Retrofication.co.uk.

I'll extract the engine/gearbox and the gear shift mechanism from the donor so we can trial fit to the Mk1. Panel shop say they're pretty busy so not sure of timing but I'll try to keep things rolling.

The L280 1.8T – Littco turbo is no longer available ("Sorry, we no longer sell the L280") but I'm still on-board with Gavin's advice so that means an alternative K03 hybrid turbo. I'd prefer torgue and smooth delivery rather than the infamous K04 sudden rush and I can't imagine I'd want anything more than 250HP ... but I'd be interested in choices that not trap me to that max.
A simple google search on K03 hybrid for AGU shows a variety available (mainly in the UK) ... but which one? I know little about turbos so recommendations that fit requirements will be appreciated.

My other thoughts on this are:

2.5" exhaust seems the common choice - I want the car fast but quiet!

Downpipes are interesting. Any comments on these (or alternative recommendations)?
Mk1 2.5″ Turbo Downpipe w/ Mk4 1.8t Engine w/ “02A” or “02J” - Techtonics Tuning
2.5" 1.8T k03 K03S Conversion Downpipe - VW Golf MK1
– Mpdevelopments

Air Conditioning (heresy for most but I'd rather AC and buy more horsepower to compensate for the power drain and weight gain). I know only LHD cars came with AC but has anyone toyed with AC in a RHD ... and not used a generic (and bulky) under-dash evaporator, or consumed the centre console with a box evaporator? I'm boldly assuming the compressor and mounting bracket on the mk4 golf donor can fit in the mk1. Any confirmation on that?

Tom.