Adam's Mk4 Gti "AGU big turbo Build thread"

[TougeMk4]

Hello everyone,

I'm Adam

Ive decided i would create a build thread for those of you who are interested.

I have popped in and out of these forums at times and during the beginning of owning my golf I had some bad gearbox troubles and had a lot of help and support come from this forum, namely bug_racer , golf loon and j mac. These blokes are all really good people and were there with all the answers and assistant. Thanks Guys

The car had become somewhat of a shopping trolley for me and my partner. She didn’t drive and so the poor golf became the workhorse of a young couple and it has been neglected a bit over the years. I always wanted to go big with this car as I love it so much but the last few years was just not the right timing or even achievable.. but the year is 2013.. and I have finally the time now to see to it that my golf gets a huge overhaul, including rebuilt Forged motor. Large turbo and custom tuning.
If you’d like to follow, id love to keep you all updated in my progress along the way.

Starting with….

THE NEW ENGINE.

I was lucky enough to pick up and engine package here on the forums. Its another AGU. As is what I have already in my mk4 golf.


My plans:

Rebuild the motor

IE Rods
JE Pistons (or some other brand)
Alc race bearing
Arp head studs
Gates Kevlar Racing belt
NEW : water pump, oil pump, pully tensioner, roller bearings and gasket kit inc head gasket
Gonna leave the head stock.. ( for now anyways) Its an AGU so its already a big port.

Auxiliaries:

Bosch 044 inline Hi flow Fuel pump
Larger MAF housing yet to be decided
Larger injectors probably in the 550cc range for some overhead space
Front Mount ( already installed )

Turbo setup:

GT2860rs A.k.A Disco potato or 2871R or..... GT2876 (GT30r)? to big?
High mount Exhaust manifold
Chasing 350+ HP

Exhaust

3” turbo back.. BUT I want this as QUIET as possible.. Ive had a quiet exhaust on this car for quiet some time and have come a custom to the engine noise and very low and quiet exhaust noises. Plus ive never have the police take a second look at the car despite the front mount intercooler. I believe the loud noises just makes you a larger target and id prefer not to get harassed on the way to work every day. But a litte growl wont hurt


Tuning.
Custom Code.

Spoke to Gavin, he is the man with the plan, and is going to take care of me one this one. Was a little worried as from what I found , the AGU are not highly cater for in the Large Turbo tune world. Eurodyne has one a stage 1 map. And I’m still yet to hear from Unitronic. Most other I have looked into really only cover a stage one or possible two map with a Drive by Cable AGU motor.

Start of my New Project.. PROJECT “AGU Big Turbo” I decided to name it fittingly for anyone searching for AGU specific build threads and information on the tuning available to them.

Happy Days I got the engine all strapped down for me ready to go from Andrew.



Craning the new lump



What a messy looking engine!! Soo many bloody pipes



I begin the strip down



The clutch looks pretty catus.. look at all the heat strees fractures in the pressue plate





Getting there..



Almost stripped back to a long block




After removing the exhaust manifold I found cylinder 4’s exhaust port was moist with oil and no where near as clean as the other three cylinders. i’ll have a chance to inspect this later as I take the head off later for rebuild.



Large Port AGU HEAD.. mmm just look at the size of those intake ports.





Ive Place my First order for this build with ECS Tuning parts. Should be here in a week or so. Ill post some update photos when it arrives. 




Started Polishing up some bits while I wait for my goodies to slowly arrive.




I'll try take better photos as i progress. im using my iphone and its not really a camera!!

Thanks for reading.