Lowdaily's GT30R Passat build

[Lowdaily]

This is my build im currently doing to a 2003 VW Passat FWD 1.8T. Currently in slow progress but will remain been carried out shortly because getting the parts shipped over from states is a nightmare also the huge import duties.

A list of most of the things im doing to the engine.
AWT rebuilt head - Changed to a big port AEB
AEB inlet manifold
EuroDyne 630cc Suite
Siemens DEKA 630cc Injectors
Miltek 2.75" Non Resonated
Reborred 06A Block
ATP manifold T3
Tial Wastegate 38mm
Garrett GT3076R 82a/r housing
Inlet Valves IE / Inconel Standard Stainless Exhaust Valves
Titanium Valve Retainers
SuperTech Valve Springs and exhaust seats.
S4 Fuel Pump SOLD changing to a Bosch 040
Cat Cams 3653 Changed to 3652's
Mahle 82.5mm Pistons
Eagle 20mm Rods
OEM Timing Belt -
Adjustable Timing Pulley
DMS Motor Sport 600bhp Head Gasket
Boost Brothers FMIC
CMI Engineering Oil Cooler Kit
CM stage 2 Clutch and Lightened Singlemass Flywheel balanced
OEM Thermo Stat
OEM Water Pump Metal Impellar
OEM Oil Filter
OEM Seals/Gaskets
OEM Head Bolts

This is how the Passat looked before it was stripped. Looked OK just didnt perform just a Resonated Miltek and a Forge DV. So it called for big plans.
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Then the engine was pulled with me an a friend who works for AUDI. Cheers 'Dan'.

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This is a few pictures of the stuff ive recieved up till now.
Theres a few things i would change like Headbolts before the head been put back on as i bought some stuff for my other turbo plans which was 2871R ATP housing sold that and got the the 30R. [wrench] [drive]

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Sanded down the bell housing to Polish.

Just been to get the atp mani milled out to size of the gasket as it was way off casting is rubbish having the turbo housing to match.

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[pipe7284]

excelent built, cant wait for the results.

Mods please move to the project/builts side.

[Seerlah]

What head are you going with? Nice build, BTW. And ATP is known for bullcrap like that. Mainly not having things lined up and their manis were always known for the flange issue, which they never seemed to correct. Only thing they did correct was a revised version from their last one that seemed to have a high rate for cracking. Should have looked into the PagParts mani, but too late now. Good luck putting everything back together.

[Lowdaily]

excelent built, cant wait for the results.

Mods please move to the project/builts side.

Had to put here they wont allow me access to put it in the build thread so take my chances to get it moved lol

[Lowdaily]

What head are you going with? Nice build, BTW. And ATP is known for bullcrap like that. Mainly not having things lined up and their manis were always known for the flange issue, which they never seemed to correct. Only thing they did correct was a revised version from their last one that seemed to have a high rate for cracking. Should have looked into the PagParts mani, but too late now. Good luck putting everything back together.

Well we would all love a equal mani but the $$$ and shipping im looking at near on $2k so the crap ATP will have to do im affraid. :(

Ive got a standard AWT head but be nice for a new one like a AEB.

[dcampana]

looking good man... should be a monster for you;)

are you going to use the larg port head or small port? also, you going to change the valves or springs? i would assume so, but.....

[Lowdaily]

looking good man... should be a monster for you;)

are you going to use the larg port head or small port? also, you going to change the valves or springs? i would assume so, but.....

Yes there been replaced ive said above, with Integrated Engineering 3 groove valves and Exhaust are 3 groove Inconel.

[SpoolinPelican]

All that money into everything and you went with an Ebay SSK? Not trying to be a buzzkill, def a nice build!

[Lowdaily]

All that money into everything and you went with an Ebay SSK? Not trying to be a buzzkill, def a nice build!

Whats a SSK?...

[SpoolinPelican]

Short Shift Kit

[A4Rob]

Moved to Projects. Nice build!

[dcampana]

sorry low daily.. appears i need to go to school again.

looking forward to the outcome!

[Euro-Tuner]

Looking forward to seeing how everything comes out! What power goals? You should be able to see over 400 to the wheel with your drive train and 82 a/r housing.


All that money into everything and you went with an Ebay SSK? Not trying to be a buzzkill, def a nice build!

So? Lots of people have gone that route and been happy with them.

[dcampana]

Euro- that is what he was hoping for. from what i recall.. should be a fun screamer on the highway.

[Lou_B5]

dude get ride of the S4 Fuel pump.
RS4 pump can not handle more than 15lb on my set up. I have a bosch 044 on the way.

with cams you get more airflow as well as you increasing the bore only makes for ensuring you have enough fuel coming out of the pump.
fyi http://www.youtube.com/watch?v=yWBAmA59m9Y

[Lowdaily]

Looking forward to seeing how everything comes out! What power goals? You should be able to see over 400 to the wheel with your drive train and 82 a/r housing.



So? Lots of people have gone that route and been happy with them.

The 'SSK' works alot of people use them on here even i thought it looks a good kit to alot of assembly to do though.

As for the power im hoping for 400-450whp if it was 450 id be more than happy, im not running meth or NOS as this is a daily driver.


dude get ride of the S4 Fuel pump.
RS4 pump can not handle more than 15lb on my set up. I have a bosch 044 on the way.

with cams you get more airflow as well as you increasing the bore only makes for ensuring you have enough fuel coming out of the pump.
fyi http://www.youtube.com/watch?v=yWBAmA59m9Y

I bought some of the stuff for my 2871r build, but have sold that an gone for a faster route with the 30R so some of the stuff ive got will have to be changed the S4 fuel pump was going cheap at the time too. I will look into that. Thanks

[Sales@RAI]

Why a stage 2 CM? That's a bit weak for your goals, no?

[dcampana]

CLint- he is FWD so not as much load... i would assume otherwise though and have a stage 4....

[Lowdaily]

Why a stage 2 CM? That's a bit weak for your goals, no?

Said it was rated to 450bhp? I think its a stage 2.

[Lowdaily]

Havnt made progress on the engine much, but ive been fitting my air ride. Im running a 8 valve setup all 1/2" connectors and lines. 10 Gallon tank with a 444C Viair compressor, i have a pressure switch cutting off at 200 psi.

[Lowdaily]

Also got a package today from US got myself the tial 38mm wastegate will crack on with engine when my uprated bigend shells come from IE.

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[Lowdaily]

Got another package today got my cams and gear of pmoss 3652 cat cams and adjustable gear.

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[Lowdaily]

Oh good people IE my resistor for secondary air pump and shells come today means i can continue with the build!!! Build is been done in my bedroom so when pistons an conrods are in i will bring my engine stand up stairs to. Sex Sleep Eat VW. [rolleyes]
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Got started today and upto now filed piston rings, 3 pistons and inn. 4th top ring started on will be all in today and then i will finish the head of tonight starbucks might help abit.

Lube'd the shells up.
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[Lowdaily]

I GOT THAT AEB, local junk yard and a $180 later i got myself the AEB head, fuel rail, injectors, throttle and intake. Yeah man.

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One question about the 06A block when using the AEB head what would i do different compared to having AWT head anyone answers would be greatful and whats the gains am i looking at getting this head.

[Lowdaily]

Ok well got the heads stripped today took all the valves and valve springs from the AWT head just had them all machiened and ground in then assembled doh!. Now i have the AEB everything over again so i removed everything from my AWT head and parceling up again with the AEB head to be assembled with my uprated valve train. Going to clean it like i did with the AWT before it goes to the machiene shop. Also picked up the flywheel yesterday from been balanced. Got engine on stand and all the pistons and conrods in, finally making progress. Should pick AEB head back up in next week or so.

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[wrench] [:)]

[Lowdaily]

A little update been a while since i have done anything ive been held back from Techtonics Tuning I ordered stem seals to have my head rebuilt with full SuperTech Valve train. Ive only just found out today theve been stuck in customs for about 5/6 weeks so i have TT send them through UPS next day so ive finally got a set and now getting my head rebuilt this week. Just got my inlet mani back today from a local engineering shop had it boxed 4" im pretty sure this will be better than a stock one its a AEB core may have to adjust the piping from the IE to fit though. It isnt pretty but aslong as it does the job only cost little money like $80 may make it fancy when engines running with another AEB inlet mani.


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[Lowdaily]

Progress update,

I got the AEB head back from the engineering shop machiened and properly seated valves, fitted supertech springs, exhaust seats and titanium retainers. It was then time to get the Head to mate with the block.

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It was time to get the motor outside and finish up in my garage. I got the bottom end all torqued up, along with the head torqued up so im just really assemblying the motor now.

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Right so was time to get the Oil pump on I sealed up with Dirko and a New OEM Crank shaft seal (The Passat hasnt done many miles i thought id get away with using the same oil pump and tensioner, but likewise i just ordered a new oil pump and got a VW genuine oil chain tensioner playing it safe i think)

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[Lowdaily]

I got this mani for $150 which i thought was a good deal its a T25 Fast Intentions looks really good quality snatched it off Ebay. Yes i have a T3 Flange on the turbo i think its worth spending money on this manifold to make it a T3 than a crap ATP. Did a little test fit got a bolt in it and it fits there clearance, Ive taken the mani to well known engineering shop so should be right when it comes back same place who did the inlet mani turned out great for little money.

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Lopped the T25 flange and wastegate off. Went down to machiene shop to get a water cut T3 flange cut.

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[Lowdaily]

Recieved a nice package today from IE Timing Belt kit, Looks a good product.

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[Sales@RAI]

love that IE kit.

[Gaberossi]

what do you guys think about that IE Timing belt Tensioner? i am thinking about getting it for my BT build

[Lowdaily]

what do you guys think about that IE Timing belt Tensioner? i am thinking about getting it for my BT build

I Found it looks a good product an IE told me the benefits are theres more wrap on the crank gear. It just looks pretty on your engine rather than a leaky ugly hydraulic tensioner. I also found the kit is cheaper for me to get this than a Hydraulic Tensioner, Roller and Belt i think its a good price.

[Gaberossi]

Is it safe to run this Tensioner on a Big Turbo daily driver?

[Lowdaily]

Is it safe to run this Tensioner on a Big Turbo daily driver?

Sure, dont see why not.

[Gaberossi]

sweet...I'm getting one

[Lowdaily]

sweet...I'm getting one

Sweet. $65 just for the tensioner.

[Lowdaily]

Right i got my manifold back today cost like $70 but looks a tidy job i think and no fits a T3 frame turbo without really restriction on flow. I just need to tidy up inside with my dremel and should be a decent manifold for a total of 260 bucks which i thinks good going!

See what you guys think huh?

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Right i painted some of the engine bits the same colour the cars going Sprint Blue. I think it looks well and 1st time i got to play with my new guns!

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Heck my Foose guns work great do a great job everytime! SATA's

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[A4DRIVR]

Just an FYI...
If you painted the back side of the accessory mount, you are going to want to clean the paint of where the bracket touches the short block. Also, you will need to clean off the paint where the alternator mounts to the bracket since the bracket provides the ground connection to the alternator. I learned this one the hard way on my own... and it's much easier to fix this now, rather than once it's all bolted up and back in the car. ; )

[Lowdaily]

Thanks for the advice but ive beaten you to it as i saw this in your thread when i read through it! haha

Whats a FYI?

[A4DRIVR]

Now that's kinda funny!

Oh.. and an FYI is "For Your Information"

[Lowdaily]

Ah i see!

Heck ive just sold the 30R tomorrow got a good price, now what turbo shall i play with at the front wheels a 35r i was thinking on the new mani.

[Lowdaily]

I got some more work tonight fitted the new oil pump, it was old and its worth changing as the Passats are hard to replace without lifting engine out i know my 1.8T hasn't done a lot of miles but its worth doing. I then got a OEM oil pump from TT engine code. I went to my local VW dealership and got a new tensioner too. You can see for yourself were this is going i must have over 100 receipts now from VW. #:-s

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Fitted the new oil pump and tensioner.
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I had to tidy the inside of the exhaust manifold with a dremel so it doesn't have any restrictions. The channels through now run really smooth as they should with no bumps or pits from the welding.

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[rogerius]

now that u are at it , u better think of a bracket to support the turbo and the exh. mani