iv had a look about and found plenty of polos with them in but no real explinations of the work carried out

in the coming months i will be buying a mk3 and my polo will be no longer needed and not worth anything too sell so me and my mates fancy taking on a 20vt conversion

plan is too buy a passat crash damage too use.. is this going too be the correct engine ? is there a certain passat engine too look for?

my mate knows all the technical stuff like how too locate driveshafts and things and I'm a fabricator so will be able too make up engine mounts and cut and weld the chassi too suit .. but when people have done this what work is needed?

such as....

do they run a subframe that i will need too adapt too fit ? will i need too cut any of the bay away too make it fit? and so on...

i know people always post about these and they get the same response "search around" but iv done my searching .. iv spent most the night and about 10 cups of tea just looking at how turbos work as i know nothing about them .. and iv had a look at a few build threads but none iv looked at have really shown exactly what theyv done just a photo of the final product...

cheers for any help...

even a username i could pm too ask about such a build would be helpfull

Passat 4 cylinder 20v engines are longitudinal so prepare for some serious fabrication to the transmission tunnel and the entire front end. be easier just to buy a passat.

If your going to use any engine then its the V5 20vT from an A3 or similar at least its already mounted transversely but your still talking a fair bit of fabrication to mounts and the like.

Edited 29 July, 201115 yr by Cymro

Join the club! To cut the long story short all those people (that made the conversion) have paid a large amount of money and they are not willing to share that knowledge. There are some bits and bobs around but when you come to ask for a photo of an engine mount and if it was crafted or it is an OEM part you get nothing back. If you ask what is the gearbox code you used they say it is the one that comes with 1.9lt TDI engine on golf and polo. Daaa there are like 20 codes for that gearbox! Anyway all those people that want to make the conversion and haven't can make a thread and gather all the info and pics they can found. I have like tons of them but we can get it down to part numbers and parts needed.

I'm sure there is more info around, look for Jarno6n on here he made a thread of behalf of his thread Jeroen for a 1.8 20vbt (bi turbo) and the pics are pretty detailed.

as mentioned previous passats are longitudinally mounted so could be a ball ache. also ask Panda.

I'm sure there is more info around, look for Jarno6n on here he made a thread of behalf of his thread Jeroen for a 1.8 20vbt (bi turbo) and the pics are pretty detailed.

as mentioned previous passats are longitudinally mounted so could be a ball ache. also ask Panda.

Passat 1.8 20v engines are a ball ache in a passat never mind a polo

I dont think its a case of they have the knowledge and wont share, its more they paid someone masses of money and have no idea what they had done lol.

to start with as stated you dont want a passat engine as they mount differently...either and Audi A3, Golf mk4 or Ibiza cupra (obv 20vt) and your onto a winner.

the two people that I know of with relative knowledge are:-

Panda - as he has one and spends a lot of time under his car and also his mates built a 20vt lupo

Dubbprince - as hes that way inclined and I believe in the process of doing this conversion himself

I dont think its a case of they have the knowledge and wont share, its more they paid someone masses of money and have no idea what they had done lol.

to start with as stated you dont want a passat engine as they mount differently...either and Audi A3, Golf mk4 or Ibiza cupra (obv 20vt) and your onto a winner.

the two people that I know of with relative knowledge are:-

Panda - as he has one and spends a lot of time under his car and also his mates built a 20vt lupo

Dubbprince - as hes that way inclined and I believe in the process of doing this conversion himself

Mate if I pay 5000 to 9000 Gbp or Euro for a conversion and I ask the garage responsible for a list or spare parts I don't think they will not provide it. If I ask you for a gearbox code I don't think it is impossible to learn it.

Some people have used the TDI gearbox and they claim that the engine can be mounted with the standard TDI mounts. So what are the part numbers of the mounts? I am currently at work but since someone has mention it and draw some peoples attention (cause I didn't sometime ago... Link) I will try to post in this thread all the material I have gathered and make a thread that will hopefully help people. The objective is this to gather all the required info (down to part numbers) so it can become a sticky and help others.

Edited 29 July, 201115 yr by Capamaru

right so i want too knock the passat idea on the head and look for a audi A3/ mk4 golf or ibiza ? crash damage obviously too make things cheaper lol but want too buy the full car then i have everything i need...

fabrication is no worry too me at all as iv done a couple of mounts in cars for friends now and I'm getting quite good at making custom mounts the hard part is locating the driveshafts and positioning the engine...

i will have a look at the threads mentioned and i will continue my research :) then once i know what i need too do i will have too keep my ebay eyes out for a breaker :)

thanks for the replies been alot of help thanks

I dont think its a case of they have the knowledge and wont share, its more they paid someone masses of money and have no idea what they had done lol.

to start with as stated you dont want a passat engine as they mount differently...either and Audi A3, Golf mk4 or Ibiza cupra (obv 20vt) and your onto a winner.

the two people that I know of with relative knowledge are:-

Panda - as he has one and spends a lot of time under his car and also his mates built a 20vt lupo

Dubbprince - as hes that way inclined and I believe in the process of doing this conversion himself

Mate if I pay 5000 to 9000 Gbp or Euro for a conversion and I ask the garage responsible for a list or spare parts I don't think they will not provide it. If I ask you for a gearbox code I don't think it is impossible to learn it.

Some people have used the TDI gearbox and they claim that the engine can be mounted with the standard TDI mounts. So what are the part numbers of the mounts? I am currently at work but since someone has mention it and draw some peoples attention (cause I didn't sometime ago... Link) I will try to post in this thread all the material I have gathered and make a thread that will hopefully help people. The objective is this to gather all the required info (down to part numbers) so it can become a sticky and help others.

that would be most helpful thanks :)

bear in mind a mk3 ibiza is only 150bhp to start with, better off with one with more horses to start with

I'm running a Mk2 golf subframe with modified Mk4 Golf engine mounts welded to the Polo shell, I've gone for the 5 speed Golf 1.8T box in place of the 6 speed audi box that was on the engine as it's smaller. The drive shafts are a modified combination of Audi 80 and Mk2 Golf parts. Its a right pain to do as you need almost a totaly new loom, peddle bo as well as they are DBW.

The AGU is cable though, no?

i was gonna say, not all 20vts are dbw...agu has a cable, and is meant to be stronger than bams etc

iv had a look for the usernames mentioned using the forum`s search function but i cant seem to find any build threads by them or anything?

i found a few posts by panda in topics like this one but nothing helpful ..

the new loom wont be a problem as i always planned too strip the polo down to a shell and just basically put the complete car i use as a donnor inside it..

me and my friend have just done it with a polo into a caddy and it was so much easier too do than trying to adapt plugs too suit sockets there not ment too go in in the fusebox and things like that...

are all the mentioned engines ran on sub frames? as really the starting point will have too be getting the subframe in there ...

The AGU is cable though, no?

Posibly I've only got the BAM in progress, so I can only speek from expereance on that.

Best bet for the subframe is a Mk2 Golf or Mk3 Ibiza as the others are too wide (I have a Mk 4 Ibiza subframe in my 6N2 and that is running some mega negitive camber even after fiddeling with the top mounts.)

i was gonna say, not all 20vts are dbw...agu has a cable, and is meant to be stronger than bams etc

I have heard this too, but supposedly BAMs are easier for bigger power?

According to this, the AGU and AJH are transverse with cable throttles, so they may be the best place to start?

Edit - link. http://www.qpeng.com/faqs/engine_faqs/all_..._they_mean.html

Edited 29 July, 201115 yr by Polio

I'm currently in the process of doing the conversion, my thread will basically have all the general bits of info on it when i finally start dropping the engine in. If you need anything more whilst I'm doing it feel free to ask away, Pm mind

Edit: I'm using an AGU Engine and box from a 1997 Audi 1.8T

Edited 30 July, 201115 yr by Mattnaz

cool cheers matt.. will be a month or so before i start my shopping so ill give you a pm in the coming weeks :) going too keep the reseach going until then just too get a good knowledge of the different ways people are doing these sorts of conversions :)

Not a problem mate, its been done before so I'm not bothered about sharing information :)

Mines in the bodyshop at the minute so itll be a week or so before i start getting to the nitty gritty, just keep an eye on my thread over the next few weeks (Y)

If you'd like some info, add me on facebook- sanjay k (location northampton- home town preston, lancs).

You'd be best off ringing me, as i hate giving people a giant list of whats needed and they find out its above their means money wise.

I'm currently working on converting No.1Naz's polo mk4 with a donor BAM coded TT engine (mapped to 280bhp)- the box we opted for was a seat ibiza/polo gti 5 speed 02R box.

I'm ordering the Audi/VW bracket that will allow fitment of the drivers TT mount and welding in a thick plate with captive nuts on the passenger side leg after cutting off the stock mounting points on the polo 6n legs.

The dog leg mount will be another bracket with extra bracing welded to the bottom of the subframe, ready to accommodate a VF Engineering dog leg mount.

I believe this setup will be solid and safe.

Having an experienced (10yrs) Audi Technician, Skoda Technician (12yrs) and now a Volkswagen Master Technician (over 15yrs) on hand...wiring shouldn't be a problem for me, after we send the ECU off to get de-immobilised and certain systems shut down- Badger 5's Bill knows his stuff on what can be done and what can't...so already worked that out via clubgti (which i strongly suggest you join and look at).

This will mean we can run polo gti clocks, i can then work out how to make the DBW pedal work as the TT pedal box is somewhat a bit of a shitter to fit without a lot of work...

The shifter mechanism is pretty easy to fit and bolt in with some brackets welded to the centre tunnel.

The exhaust system will need to be done by a pro, but a quick setup can be knocked up pretty easily yourself...i recommend a 3" downpipe to 2.5" back depending on the engine output.

Fuel pump will either be a 225bhp TT one if it fits the polo's tank, else a VR6 golf mk3 one adapted to fit...

I'm yet to try the skoda clutch mechanism convertor on the gearbox- this will convert a hydraulic clutch mechanism to cable at the gearbox end.

Another few things- a VR6 mk3 radiator (mk3 with aircon) will bolt straight into the polo 6n slam panel and combine that with 2x12" pacet/kenlowe fans and you're away...i haven't figured out rad hoses yet but i think i will opt for some mk2/3 golf rad hoses.

Driveshafts- these need to be professionally made if you dont find a set that fit properly...luckily the box we're using already has 100mm flanges, so its a case of using shafts from other vag cars to pull it off- If Depression-Tim can give us a few details on the audi 80/mk2 golf shafts he has then this will be covered off too...

I am also planning to use a seat leon cupra r master cylinder since it is a little bit more stubby compared to a polo one and shouldn't touch the cam cover if the engine is pushed back when mounted.

I plan to also re-work the brake lines so they run like they do on the TT and use plenty of heat shielding to shield them from the turbo/manifold.

I have seen a variety of ways to mount this engine/box combo into a 6n/6n2 and have built up over 5yrs of research on engines, boxes, mounts etc...just not tested it all myself, once i'm done i'm hoping to offer this conversion to club members at a discounted price compared to the big names.

There is a way you can do minor fabrication to create your own mounts using polo 9N GTI drivers mount (this will bolt onto the stock mounting mounting point) and for the passengers gearbox top mount, you can use a 16v mount, cut the cylinder off the gearbox bracket and create a new box section mount and weld the cylinder back onto this but obviously in the correct place. Then its a case of either using the dog mount as suggested above or using a custom made front subframe like a mk3 golf.

There are people out there that will do the wiring loom and de-immobilise the ecu for approx £400, the shafts can be made for approx £320-400 (some cheaper), the engine and box should come in at around £800-1200, rad and fans-£150-200...you get the idea.

Sanj.

Basicly they are Mk2 Derv Golf shafts with Audi 80 (or was it 100? I think 80 sorry its been rather a long time in the making) flanges on the gearbox side, they were made up by a local specilist (part of the GKN group) running to matching Mk2 Golf hubs.

sanj what you have just said has been like a wet dream too me :) youv give me like 80% of the infomation i needed

the driveshafts arent a problem as the fabrication shop i work in had a milling shop attached too it and they are partial too a bit of dinner time work for the right price :) so should be good

really got me excited for the project now i wish pay day wasnt next month lol

thanks Tim- i'll take a look into this as i've also heard a set of rear golf mk2 syncho shafts also work well. Personally i plan to shorten the shafts myself and then have a company re-produce them as one solid balanced shaft capable of handling the torque output.

Reedy- whats the other 20% you need- perhaps i can still help?

just had another good long reed through all that pal and pritty much alot of what i need is there and after reading a few times i understand more what is needed..

are you suggestion the BAM engine and the 02R box are the EASIEST too work with or just what you opted too use?

are these 2 a direct fit with each other running standard clutch and flywheel arrangements? or require re-working?

The BAM engine (along with any other 1.8T) can use any of the following gearboxes

O2A (mk3 golf)

O2J (mk4 golf)

O2R (mk7 Polo/mk4 Ibiza)

It just comes down to preference (different ratios, strength, mileage etc) which will decide which box is the best one for you. As long as the gearboxes are 5 speed, none of them are any easier to work with as they have similar dimensions. Its just when you go 6 speed that it becomes alot more difficult

The O2A is the most common one people use.

The O2J is just an updated version of the O2A with very similar internals. Whether it is actually a stronger gearbox is debateable

We opted for an O2R box due to it being the newest of all the options (and normally lower mileage). Although I’ve read that the O2J box is rated to cope with higher power, not 100% sure about that tho.

But there is a user on here with a mk7 Polo Gti running 400bhp on a standard box with a Peloquin differential.