AGU 1.8 20v Basic Price Guide and Parts list For Conversion. Including Links

Basic Golf mk1 20vt AGU engine Conversion parts list. For AGU conversion


Engine with code AGU from an Audi a3 or golf mk4 including loom, ecu, turbo, ancillaries (donor car or package) mine was £500 Delivered! from ebay  for everything I needed from the donor car. http://www.ebay.co.uk/itm/370708133039?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

02a or 02j gearbox if you want to upgrade (recommended) you will need the gear shifter from inside the car also and suitable clutch and flywheel depending on which box you go for.
If you want to use these boxes you can buy these mounts £150 -  http://www.ebay.co.uk/itm/VW-GOLF-GTI-MK1-G60-1-8T-20VT-02A-02J-GEARBOX-BRACKETS-MOUNTS/181063902229?ssPageName=WDVW&rd=1&ih=008&category=43120&cmd=ViewItem

There are also several gearbox codes within the 02a and 02j boxes which produce very different gear ratios:

02a/O2A Gearing/Gear ratios, $Prices$, and other helpful hints | VW Vortex - Volkswagen Forum


I am using the original 020 gearbox from my Mk1 GTI engine for now. But apparently they don’t last long with the increase in power!

Intercooler £73.50 http://www.ebay.co.uk/itm/310234340520?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

Engine mount if you don’t want to make one £80 http://www.ebay.co.uk/itm/181057739195?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

Throttle cable £13 http://www.ebay.co.uk/itm/370733401737?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

Exhaust insulation £21 http://www.ebay.co.uk/itm/260837189157?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

Downpipe from qpeng £176 http://www.qpeng.com/component/page,shop.product_details/flypage,shop.flypage/product_id,19/category_id,6/option,com_virtuemart/Itemid,75/

Cambelt – Mine was free from a mate but around £15 from GSF

16v tensioner from kr engine £23.40 http://www.gsfcarparts.com/parts/engine-parts/engine-timing-control/timing-belt-tensioner

Its worth upgrading the waterpump when doing the cambelt – around £20 GSF depending on quality. Some say metal fins is better but my old one was plastic and had done thousands of miles and in mint condition.

Aux belt – you have to remove the Aircon and power steering pump and then get a belt to fit. It’s a 6 rib belt but the length I have forgotten. Its easy to measure the length needed with a piece of string. (remember to move the aux tensioner back to make sure its not too short.) My belt was £13 from a local garage

intercooler pipework - £80 This should be more than enough http://www.ebay.co.uk/itm/390461192717?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

slimline radiator fan/fans £20 each but this depends on what radiator you want to use. Some use 16v mk2 rads and some have used the original ones. It also depends on where you want to mount your intercooler. I will be using my original radiator for now which I have figured I can just about fit the intercooler infront of it. http://www.ebay.co.uk/itm/181048094384?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

Some radiator hoses will be needed -  mk2 16v coolant pipe bottom hose and mercades 190e top hoses are supposed to be a good fit!

air filter – I already had mine, but a good quality K&N will cost around £50

You can reuse the old induction air pipe but lots like to upgrade. £60
http://www.ebay.co.uk/itm/310510624302?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649


New clutch – depends on quality. Some say to use a sachs clutch, but then some have said this makes the pedal very stiff and can snap clutch cables! Probably best to go for the 02A Gearbox conversion. Probably looking at £50 ish for a clutch

My wiring cost me £230 including the ECU decode. This was done by a company called Vagtronics. All you need to do is connect up 4 labeled wires to the fusebox. Easy
 http://www.facebook.com/pages/Vagtronics-Vehicle-Electronics/250056438454452?ref=ts&fref=ts

You can do you wiring yourself or contact a member on here called rubjonny. He makes plug and play looms for whatever you need but is always booked up for months. You can also run megasquirt etc if you have the knowhow
Heres the link i found with the best wiring info! its a long read!
http://www.clubgti.com/showthread.php?205887-OEM-management-wiring-1-8T-gt-Mk2-harness-install-FAQ

100mm driveshafts and flanges are recommended. Depends on which gearbox you go for etc
http://www.ebay.co.uk/itm/150970980241?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649

ECU re-map will cost around £200 to get more than £150bhp

When re-using the old engine mounts, its important to upgrade/renew the mount rubber bushes. I have heard of old mounts breaking and being too soft.
I opted for a full polybush kit at £130
http://www.ebay.co.uk/itm/390379025436?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

Brakes should be upgraded as if you own a mk1, you will know that the standards are not that great. Again there are several options including Vauxhall fronts and mk4 golf rear disk conversions which can be picked up from breakers yards pretty cheap.
Most would uprate the suspension to coilovers which again is down to what you want and how much you want to spend.


I have probably missed some bits but this gives you an idea.

So as you can see its not the cheapest conversion and you can easily spend much more than this depending on how far you want to go with it!

I will keep updating this as I go along with my build and then Im going to write a step by step guide on how to do the engine conversion even though its not too tricky!

Feel free to correct me where I have gone wrong and I will correct it.

Take a look at my build and see what you think.

http://vwgolfmk1.org.uk/forum/index.php?page=topicview&id=your-mk1-golfs_2%2Flhd-helios-blue-mk1

Cheers






 

Nice guide mate. Good work.      

Some radiator hoses will be needed -  mk2 16v coolant pipe top hose and mercades 190e bottom hoses are supposed to be a good fit!

merc top hose mk2 bottom      

Nice thread!
If you run with a decoded ECU,all you need is engine wirings right?no need of clusters,keys etc etc

peterg60 said

Some radiator hoses will be needed -  mk2 16v coolant pipe top hose and mercades 190e bottom hoses are supposed to be a good fit!

merc top hose mk2 bottom      

cheers mate. edited!

ezzoG60 said

Nice thread!
If you run with a decoded ECU,all you need is engine wirings right?no need of clusters,keys etc etc

yes thats correct

You've jut saved me a good few hours on the PC during lunch at work there  

I started yesterday gathering this type of info and banging it all into a excel spreadsheet.

Links to various parts needed and information on here and other forums, so I can start getting my head around it all.

Thanks  

Raps3 said

You've jut saved me a good few hours on the PC during lunch at work there  

I started yesterday gathering this type of info and banging it all into a excel spreadsheet.

Links to various parts needed and information on here and other forums, so I can start getting my head around it all.

Thanks  

No worries!

That's pretty much the basic list for the really needs,

sadly no one conversion is the same as the next, as there are so many ways of making it look pretty in your engine bay. This is where parts and money lead you down many different roads.

Get the engine in and choose your path.

yep true its the little bits you need as well that mount up. also i think its a good idea to open your engines up while they are out of car. ebay engines or engines people say 80k running great i wont trust no more. look what happen to me powerseller ebay  80k engine runs great got it opened it up pistons mashed valves mashed had to rebuild engine. for the sake of a few more days take head off and inspect engine rebuild it new gaskets  piston rings dont cost much nor do forged rods peace of mind.  and you know you have a good engine . plus its ready if you wanna upgrade power in futher. people have bent rods running ko3s its the torque spikes that bend rods. and trust me when i started my converstion i dant have a clue only thing i did was change oil in my subaru . so much info out there and watch these 5 videos how to fit rods and rings this is what i folllowed.

http://www.youtube.com/watch?v=JPYIUylUW9I

oh you superstar. Starting mine in the summer in my mk1 caddy (have a whole mk4 gti agu as a donor) this will be most helpful!

Glad its helping people out. I just wanted to show people the bare minimum that they could get away with really.
I agree that its well worth changing gaskets and inspecting engines when they are removed for the sake of a few quid!

peterg60 said

yep true its the little bits you need as well that mount up. also i think its a good idea to open your engines up while they are out of car. ebay engines or engines people say 80k running great i wont trust no more. look what happen to me powerseller ebay  80k engine runs great got it opened it up pistons mashed valves mashed had to rebuild engine. for the sake of a few more days take head off and inspect engine rebuild it new gaskets  piston rings dont cost much nor do forged rods peace of mind.  and you know you have a good engine . plus its ready if you wanna upgrade power in futher. people have bent rods running ko3s its the torque spikes that bend rods. and trust me when i started my converstion i dant have a clue only thing i did was change oil in my subaru . so much info out there and watch these 5 videos how to fit rods and rings this is what i folllowed.

http://www.youtube.com/watch?v=JPYIUylUW9I

Nice video Pete. Good find mate.

im glad ive found this thread thinking of going down this route with mine or maybe 2l 16v on carbs
keep up the good work

Good info on what is needed to get a 20vt in and running. Having looked around for a while and going over costs i've noticed the Vagtronics prices have spiralled upwards!! I also found another guy doing looms/ecu decode that have your own engine loom and the donor matched so your oil, water etc all work. Same as Rubjonny does. Now that would save more hassle and time.
Link: http://www.ebay.co.uk/itm/111160985124?ssPageName=STRK:MESELX:IT&_trksid=p3984.m1555.l2649

I think Rubjonny is booked out solid until Feb next year!

now then, im doing a 20v conversion but im using the mk4 o2j gear box. are there specific drive shafts I know ill have to use 100mm flanges. thanks.

You need drive shafts from a post 84 Cabby for the conversion

or super rare early b3 passat with rubbish engine 90mm 02a flanges. will only work on early type fixing 02a box though, later/02j are different.

you can actually buy them from vw still but cost you more than a set of 100mm mk1 shafts will

thanks lads, there will be many more questions coming your way.

Really helpful thread, has saved me plenty of questions!! Am currently in process of a 1.8t conversion into my mk1 caddy, am just abit stuck on finding what clutch to use? i'm planning on using the mk4 gearbox (O2j I think?)

Any help would be much appreciated!