1.8T 20V SWAP INTO A1 CHASSIS - THIS PAGE IS NOT DONE YET


ENGINE

There are several key decisions that will need to be made before you can begin your swap.  The first two, which are independent of one another, are the engine and tranny.  Subsequent choices will follow depending on which engine and tranny combination you use.  There are two main groups of 1.8T engines:  The earlier version, which was designed for longitudinal applications (ex. AEB) and the later version which was designed for transverse applications (ex. AWP).  I will briefly discuss a few pros and cons of each, using the AEB engine as reference to the logitudinal group, and the AWP engine as reference to the transverse engine group. 

ENGINE
 PROS
 CONS
AEB
(earlier version)
 Larger ports Stock intake manifold can't be used because the engine is designed for longitudinal applications.  An intake manifold from a transverse application (AWP, AMU, AMB) needs to be used intstead.  Because the ports on the transverse engines are smaller, there is a step going from the block to the intake manifold.

Stock PS engine mount can be used
 Uses the K03 which has less air flow capacity and therefore is capable of holding less boost than the K03s.

Earlier version of Motronic is used which doesn't have the immobilizer

Cable actuated throttle



AWP
(later version)		 Stock intake manifold can be used since the engine is designed for transverse applications Stock PS engine mount must be modified

Uses K03 Sport turbo which flows more air and is capable of holding more boost
 Later version of Motronic is used which has the immobilizer


Drive by wire throttle

To summarize.....

The AEB has larger ports, however the stock intake manifold can't be used because the engine is designed for longitudinal applications.  An intake manifold from a transverse application (ex. AWP, AMU, AMB) needs to be used intstead.  Because the ports on the AWP are smaller, there is a step going from the block to the intake manifold.  Those engines which were designed for logitudinal applications and also have an external water pump, use the stock A1 passenger side engine mount.   You do not have to deal with the immobilizer issue, nor the drive by wire throttle.

The transverse application engines have smaller ports but the stock intake manifold can be used allowing for a smooth transition between the block and manifold. 


AEB PORTS
 AWP PORTS

AWP AND AEB INTAKE MANIFOLDS



TRANNY

The choices for tranny are the 020, 02A, 02J, or 02M.  The 020, 02A, and 02J are all 5-speeds and the 02M is a 6-speed.  The stock 020 can be used with a 1.8T in terms of bolting up to the block as well as handling the increase in horsepower and torque.  When the 020 is used, the drivers side and rear mounts remain unchanged of course.  All other tranny installations will require custom driver's side and rear mounts.  For the 02A, you can actually purchase these mounts from individuals or perhaps companies are making them by now.  The 02J and 02M (at least when I was needing them) require custom mount fabrication to be done yourself.  The 02M furthermore will require custom drive axles in terms of length and something would need to be done about the drive axle flanges because they are 108mm instead of 100mm.


MY SETUP


 SPECIFICS
Engine
 1.8T 20V: Engine Code AWP
Engine Managment DTA P8PRO
Intake Manifold
 Stock AWP
Throttle Body
 ABA (has same bolt pattern as stock AWP, but is cable actuated)
Throttle Cable VR6 Corrado
Fuel Injectors 580cc
Fuel Pump Stock '79 CIS fuel pump
Fuel Pressure Regulator
 Stock AWP FPR (3 bar)
Exhaust
 2.5'' Exhaust system
Downpipe
 2.5'' Custom fabrication
Turbo

Compressor: GT30R -10, mitsubishi compressor cover
Wheel Diameter: inducer size - 2.08, exducer size - 3.00, Trim: 48

Turbine: GT30R turbine wheel, .48 T3 turbine housing
Wheel Diameter: inducer size - 2.03, exducer size - 2.22, Trim: 84

Intercooler
 6'' x 17.5'' x 2.25'' core area
Tranny 02J: EHA with Quaife
Clutch
 Hydraulic:  VR6 228mm Clutch with single mass 14lb flywheel
Clutch Master Cylinder
 Stock 02J
Shifter Mechanism
 Cable
Speedo Cable Pre-'79 1.3L European Left hand drive Mk1 Golf  Speedo Cable
Drive Axles
 100 mm drive axles with axle flanges from a DQY etc. 02J
Mounts Front: Stock
Passenger Side: Modified stock bracket
Driver Side: Custom fabrication
Rear: Custom fabrication



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