Just purchased a 1.8T BAM engine out of a TT for my MK1 Tintop project and need some advise ...

Hi Guys,

I have just (within the hour) picked up a decent 1.8t BAM engine from a mate that he removed from a written off 2002 TT .

It is the complete engine with gearbox / ko4 turbo etc etc…

The ecu , wiring loom , accelerator pedal , steering column & wheel + key , intercoolers are also included.

My question is where to go from here ? I know there are Sachs kits available on Ebay for £170 that include the G60 flywheel and VR6 clutch but what code gearbox do i need to source and are there options that bolt straight on ?

What about drive shafts , hubs , etc …?

Where can i buy engine mounts that will bolt straight in with little effort to make the BAM work in the mk1 bay ?

Jumped in a bit too quick really with this one but the engine was there and because my pal had intended to put it in his mk4 shell he has already purchased and included the required down pipes & de-cat etc… so just had to snap it up lol.

All and any advise would be gratefully received even if its pointing me to older posts that have covered this subject !

O2j/o2a gearbox and matching shifters
Single mass clutch/flywheel
Epytec for mounts
Down pipe (qpeng, trackslag etc..)
Exhaust
Late Mk1 cabby 100mm driveshafts
Ecu decoded (and mapped if you want power)
Loom modified
Intercooler/rad (standard tt intercoolers waste of time)
Suitable rad and fan(s)
Pedalbox modified for hydraulic clutch and dbw pedal.
And away you go…..(very quickly!!)

Firstly cheers for taking the time buddy (no one else has) .

Thanks for the info but can i ask what the diff is between the 2 gearboxes you have mentioned and which is the preferred as lots of diff opinions floating around out there with a diesel box seeming the most popular ?

The rest of it seems pretty self straight forward however should i also be fitting a 16v tensioner to help clearance in the engine bay ?

I will be going for max power power output with this project so a good mapping is a must

Is it a 5 speed box you have with the engine? If so use that or source an 02j box. 

I'd get this kit to physically fit the engine and box, includes the tensioner etc. 

http://www.classic-vw.co.uk/18t-install-kit-with-uprated-mounts-mk1-golf-jetta-caddy-scirocco-15279-p.asp

The box that came with the lump is a 6 speed quattro from a tt so no good for me.

The belt in the CVW kit is a cambelt, i thought that side of things was ok ?

Thought it was the aux belt etc that had the issue ?

chris1980mk1 said

The box that came with the lump is a 6 speed quattro from a tt so no good for me.

The belt in the CVW kit is a cambelt, i thought that side of things was ok ?

Thought it was the aux belt etc that had the issue ?

Scratch that last comment about the cambelt im being a dumbass lol

If I'm right, yes the diesel box is more popular, mainly because the 5th gear/ final gear has a more top end on it meaning it's not reving its tits off doing 80mph like the petrol ones do,

Also I'd say go for a slimline radiator and fan to give u a little bit more room for the intercooler

I'd go for an o2j over an o2a…..newer, easier to find and lots better shift quality. Try and get the matching shifter and cables to the box you buy.
Upto you if you go diesel or not…….i prefer the shorter gears in my 1.8t o2j box…..its still good for nearly 150mph; fast enough for a mk1 and cruising isn't too bad(been as far as Italy in mine!)
As mentioned you will need a mk2 16v cambelt tensioner which needs to be spaced out between 6-8mm from the block to get the belt running true.
Space is an issue with intercooler/rad set up…..i designed a custom one and had it made by a good friend. 
For a bit more power i'd fit a relentless pro4 exhaust manifold and an uprated TIP whilst the engines out…..both more efficient than standard and help the engine 'flow' well with big benefits once mapped. (Also hybrid turbo if you have the dollars!)
Mine was 292bhp on the rollers which makes for an interesting drive :-) 

rallye20v said

I'd go for an o2j over an o2a…..newer, easier to find and lots better shift quality. Try and get the matching shifter and cables to the box you buy.
Upto you if you go diesel or not…….i prefer the shorter gears in my 1.8t o2j box…..its still good for nearly 150mph; fast enough for a mk1 and cruising isn't too bad(been as far as Italy in mine!)
As mentioned you will need a mk2 16v cambelt tensioner which needs to be spaced out between 6-8mm from the block to get the belt running true.
Space is an issue with intercooler/rad set up…..i designed a custom one and had it made by a good friend. 
For a bit more power i'd fit a relentless pro4 exhaust manifold and an uprated TIP whilst the engines out…..both more efficient than standard and help the engine 'flow' well with big benefits once mapped. (Also hybrid turbo if you have the dollars!)
Mine was 292bhp on the rollers which makes for an interesting drive :-) 

Awesome info guys cheers for taking the time !
So i am now on the hunt for a decent low miles 02j Gearbox however if you type in that on Ebay you seem to get an array of different options like : from a diesel / from a beetle etc etc are there different varients available ?
Are all the boxes starting with 02j code cable operated and more importantly the same before i drop a clanger on the wrong one ?

That is one sexy engine bay , has that been converted to cable throttle as looks different to my set-up ?

Best thing to do is 'google' vw 02j gearbox ratios/codes to see differences between boxes. All 02j's are cable change. 
I run the earlier AGU management with a cable operated throttle. Yours will be 'drive by wire' throttle so you'll need to mount the original tt accelerator pedal to your mk1 pedal box.

Having a nightmare sorting out the right gearbox guys !
Have phoned a vw breakers near me today who want £200 for an 02j gearbox but want to know what code i am after ? I have checked the ratios on the data sheet and to be honest it all looks giberish to me lol. I can take a chance and pick one at random probably a EGQ,FBW code but what alterations will be needed with the driveshafts and cups etc and do i need the hubs from the same car to make it work ?
All the info on the forums is so out of date that people 10 years ago did not have access to the parts i can  now source .
I would rather not have to mess around with adapting driveshafts etc and just get a box/cups/shafts & hubs that will all go straight in if possible ???
If anyone out there that has done this before can tell me to go buy exactly what will suit please let me know as the project is going know where at the moment

I cannot tell you which code for the gearbox, but I think (could be wrong) that the earlier o2j box,s come with 100mm cups, later have 108mm and will need to be swapped for 100mm ones so the cabrio 100mm shafts will fit.

Just source an 02J box from a 1.8t mk4 or Audi A3 or similar.  The breaker must know where the box they have came from?  

Some come with 108mm cups, mine did, I just swapped them out for 100mm items. Then use some driveshafts from a Rocco or cabby, or buy some new 100mm shafts off ebizzle. 

chris1980mk1 said

Having a nightmare sorting out the right gearbox guys !
Have phoned a vw breakers near me today who want £200 for an 02j gearbox but want to know what code i am after ? I have checked the ratios on the data sheet and to be honest it all looks giberish to me lol. I can take a chance and pick one at random probably a EGQ,FBW code but what alterations will be needed with the driveshafts and cups etc and do i need the hubs from the same car to make it work ?
All the info on the forums is so out of date that people 10 years ago did not have access to the parts i can  now source .
I would rather not have to mess around with adapting driveshafts etc and just get a box/cups/shafts & hubs that will all go straight in if possible ???
If anyone out there that has done this before can tell me to go buy exactly what will suit please let me know as the project is going know where at the moment

I'll be honest Chris?, if you are having trouble choosing/sorting a gearbox out you need to consider if you are going to be able to do the rest…..there's lots of info/parts you are going to have to research to do the conversion, and sourcing a gbox is one of the easier parts of it! Get on the computer and read as much as you can about converting a mk1 to 1.8t. You need to do your own 'digging' for info and get a list of stuff that you are going to need. 
There is no box/shafts/hub set up that will 'go straight in'. Its mix and match…..
I converted mine nearly 10years ago and anything which is available now was available then. Its just the cost of stuff thats changed….AGU engines were £1k then, about £200 tops now! 
Good luck :-)