Audi 1.8T 20v engine tuning guide with advice & tips (2022)

"The 1.8T was my first turbo engine, and one of the best."

VAG 1.8T 20v Petrol engine as fitted to Volkswagen/SEAT/Audi and Skoda cars: 150-240 bhp from the factory.

Let's see what can be done to tune the 1.8T engine, how much potential power you can extract, and which are the best mods for your project.

I must confess I have a bias here, the 1.8T is one of my favorite engines and offers much tuning potential, and is well supported when it comes to upgrade parts.

Audi 1.8T 20v engine tuning guide with advice & tips (1)

The 1781 cubic centimeters in this 20 Valve turbocharged engine represents what must still be one of the most tunable engines around today and is found in family cars like the A3 and A4 and on sports oriented models like the TT, and the S3. 350hp on the standard block is typically the response you'll get when you ask about safe power limits when tuned.

It often features in engine swap projects such is the versatility of this great engine block. The 1.8T also featured in Wards 10 best engines in 97 98 01 02 and 03.

The fact these engines can be tuned to such extremes indicates their versatility.

See our video which covers all the principles of tuning your engine.

The 1.8T was replaced with a 1.8/2.0 TFSi version and we have a guide that covers these and the more recent EA888 version is covered here.

The 20 valves are arranged with 3 intake valves and 2 exhaust valves per cylinder. The exhaust valves are larger than the intake, and having the extra intakes allow better fuel atomization and intake control depending on the throttle and load.

1.8T Tech guide

(The exhaust valves are somewhat larger than the intakeand this intakeconfiguration makes the engine an efficient one).

The compression ratio is set to 9.5:1, but, a slightly lower 9:1:1 in the 240 bhp versions (and those with the K04 turbo), which although high for a turbo gives plenty of low down torque. (Obviously with direct injection you can run much higher compression ratios, but this didn't come in until the later revisions to the more recent engines.)

Technical information of this engine:
Bore size of 81mm (3.19in) a Stroke of 86.4mm (3.40in) and a Rod Length of 144mm
The peak power band is between 2000 and 5000 rpm, and delivers good fuel economy as well around 34-38mpg.

The turbo delivers a boost pressure of 8.7 psi or .6 bar on most variants of this engine although the 180bhp engines run 11.6 psifrom 2002.

The standard cast iron engine block is solidly constructed andcan handle power levelsup to 240bhp in factory tune and many owners have reported much higher power gains than that.

The most common turbos fitted are the KO3 & KO3s (150-180 bhp) and KO4 (210-240).

1.8T engine codes and differences

When planning upgrades it is worth finding out if your engine has the forged components already.

(Generally speaking the AGU APH ARX AUM AVC AVJ AWC AWD AWU AWV AWW BFB AJQ APP ARY AUQ BEX AMK APY APX AJH and BAM came with forged cranks but there are some exceptions to this list.)

The 1.8T engine as fitted by Audi is arguably one of the most easily tuneable engines today.

The engine code is found at the top part of the engine near the valve cover on the side etched into the head so you might have to clean it off as the stamp often gets covered in grime.

The engine codes are (This list is not exhaustive and covers the most popular engines, some engines were only available in selected markets.) Greece had an AUM block which was mapped to 190hp and badged the GT193.

Small Port size head Engine Codes: ADR, AMB, AMU, APT, APU, ARG, ATC, ATW, AWM, AWP, BEA, AWT, ARX, ARZ, AWC, BJX ,BAM, APX, AMK, BVR, AJQ, AJL, APP, BBU, APY, AUQ, BEX, AYP, AVJ

Large Port size Head Engine Codes: Typically 97-99: AEB, AGU, AFY, AJH, AJL

(Video) VW / Audi 1.8t 20v 5-600HP Engine build On a Budget

VVT was included on AUQ, AWU, AWV, AWW, ARX, AUM, AWP, AMK, BAM

Popular cars which used the 1.8T engine

  • VW Golf Jetta Bora Polo Beetle Passat
  • Audi A3 A4 A6 TT
  • Skoda Octavia Superb
  • Seat Leon Toledo Exeo Cupra R Ibiza

We have also seen some swaps on older models, where for example VW Polos and Golfs had a 1.8T engine swap.

Camshafts

Fast road camshafts usually bump the performance across the rpm range, you could drop a little bottom end bhp but the high end rpm power will be better.

Motorsport and race camshafts, bump the high end rpm power band but as a result the car will not idle smoothly and low end power nearly always suffers.

Audi 1.8T 20v engine tuning guide with advice & tips (2)

I'd never have found a Motorsport camshaft to be a pleasure to live with when on the daily commute because the lumpy idle will make the car prone to stall and smooth driving at low rpm becomes impossible. If you are developing a track car this doesn't matter as you are in the high end of your RPM range anyway and that is where you want the power to be.

Some 1.8T engines respond better to mild camshaft durations so set your engine up on a rolling road.

The map and fuel pump and injectors also will say much on the power gains you'll hit.

A fast road camshaft is one of the most effective mods you can do on the 1.8T engine, apart from a remap, or turbo upgrade. Competition cams are not great at low RPM and can be quite lump, which makes driving in traffic quite tricky and you'll need a higher tick over to avoid stalling.

A fast road cam works really well though, as it's optimized for road use, it's all about the profile you choose really.

1.8T Tuning Tips

There are some good hybrid turbo options out there and the newer twin scroll turbos are worth investigating, much depends on where in the rev range you want the power and other mods you've done.

So let's see what 1.8T tuning mods work best on this gem of an engine.

Please watch our video which covers the 5 principles of tuning your car. Be sure to subscribe and support our new channel.

Best 1.8T Engine Mods

  1. Mapping - remapping provides the most advantage in terms of cost savings, aftermarket ECUs, and piggyback ECUs are all alternatives.
  2. Fast road cams are one of the most significant mechanical changes, but they must be installed by someone who knows what they're doing and they are not always easy to source but you might find a local firm to regrind a stock camshaft.
  3. Intake and Exhaust - Note that on their own these mods will NOT ADD POWER in most cases, but they can help enhance power after other mods by removing the restriction.
  4. Upgrades to turbochargers and superchargers - forced induction is the most efficient approach to increase your 1.8T power. It is one of the most costly upgrades but provides the best gains. Swapping a K04 for a K03 or a hybrid will offer decent power gains.
  5. Head work - The goals of porting and flowing the head are to get air flowing into the engine while removing flow restrictions and turbulence.

Tuning stages for the 1.8T

  • Typical stage 1 mods often include:Sports exhaust header/manifold, Panel air filters, , Remaps/piggy back ECU, Intake manifolds, Fast road camshaft.
  • Typical stage 2 mods often include:fuel pump upgrades, induction kit, Sports catalyst & performance exhaust, high flow fuel injectors, Fast road cam, Ported and polished head KO4 turbo upgrade.
  • Typical stage 3 mods often include:Engine balancing & blueprinting, Twin charging conversions, Crank and Piston upgrades to alter compression, Adding or Upgrading forced induction (turbo/supercharger) with hybrid or twinscroll, Internal engine upgrades (head flowing porting/bigger valves), Competition cam.

Head Porting

Porting and flowing the head is really effective, and TorqueCars recommend a 3 or 5 angle valve job to maximize airflow into the engine. This will ensure the engine gives better low end torque and greatly increases its efficiency.

Audi 1.8T 20v engine tuning guide with advice & tips (3)

Enlarging the ports and ensuring a decent flow through the head really helps the engine breathe, and the 1.8T can handle around 300hp on the stock internals (depending on your engine code) but the head was not designed to cope with these power levels.

The image above shows the ports have become a fairly sharp V shape instead of the more squared off corners on a stock head.

5 valves per cylinder make valve jobs fairly specialized, but thankfully here in the Uk and other major regions there are specialists around with the tools required to extract the max from these heads. Ask our forum members for some pointers in your area and please don't attempt head work on a DIY basis.

1.8T remapping

A remap on a standard engine will typically yield around 40-50bhp increase, and, with the addition of a higher capacity turbo, a freer flowing intercooler, and efficient induction and exhaust design, power gains to around 300-350bhp are possible.

If you have a turbocharged 1.8T, your first and most beneficial mod is a remap. The appropriate map may make a significant impact in the vehicle's performance and handling.

Why 1.8T remapping works.

What is it about OEM maps that makes them so frustratingly boring? Most of the time, a single configuration for everyone entails some parameter tweaking with local fuel emission requirements and temperatures in mind when the ECU map is set up.

Temperature changes, small flaws, and adverse weather are all taken into consideration while creating timing maps. It is fairly uncommon for CO2, HC, and NOx emission targets to match across areas so VAG like most car makers adopt a one setup for all regions approach.

Manufacturers do not want consumers to be inconvenienced by mechanical or fuel efficiency issues, and since different countries use different gasoline grades and experience differing degrees of bad weather, a fudged ECU setup is required to keep things functioning well.

Depending on component quality and the quality of the parts fitted, the power of each 1.8T may vary by up to 20bhp. Instead of creating timing maps for each vehicle, they utilize a one-size-fits-all approach and some blocks have more tuning potential than others.

Which 1.8T engine codes are the best for remapping?

Remaps are available for all 1.8T engines, which enhance power by 20-30%. To fully use the horsepower from your changes, TorqueCars suggests remapping on a rolling road Dyno.

Engines with forged internals, large port heads, and K04 Turbos provide more power than other models, although all react well to remaps.

Be wary of power claims by remappers, they could just be selling you a spike and potentially bad power profile. For example if the power comes on too soon you'll be damaging your turbo as it will never properly spool down and cool off.

(Video) Complete 1.8t 20V Engine Rebuild ~ Forged Internals and BIG TURBO

Large blips also stress engine components and can exacerbate wear or at the very least cause wheelspin.

On the plot below note the differences between the red and green remap profiles, and work out which one you would prefer.

Audi 1.8T 20v engine tuning guide with advice & tips (4)

We would be much happier with the green map even though it only boasts 175hp, the 200hp map is all over the place and only has a small area reaching the headline 200hp.

Always ask to see a dyno printout from the mapping company you use and make sure the power is where you want it to be.

Expect to have to upgrade the clutch when increasing the power of the engine or the clutch life will be dramatically reduced the TT aftermarket clutches are likely to be the best option.

The stronger engines had pistons from forged Aluminum Mahle, with fracture split forged steel connecting rods mated to a forged crankshaft which is capable of handling far more than the mild 150bhp tune and retaining reliability.

K03 K03S & K04 Turbocharger guide

The K03 turbo was available from 1996 until 2000, when the K03s with more power took over.

The K03 turbos are utilized on the simpler and lower powered 1.8T engine - ie: AGU. These engines use a MAF sensor and a cable-operated throttle with smaller injectors.

The K03s turbos are utilized in AUM engines with MAF and MAP sensors. These engines employ better drive-by-wire throttle that increases reaction time, fuel efficiency, and performance.

The KO3 turbo has 12 blades, and with the right supporting mods can release power around 200bhp, the K03s has 8 blades, although lower than the KO3 the K03s will support around 220 to 250bhp.

Audi 1.8T 20v engine tuning guide with advice & tips (5)

The K04 is a larger turbo and came in three versions (some suited to the transverse engine layout in the A4)

  • K04-020 no temp gauge aperture in the housing
  • K04-022 no temp gauge aperture in the housing
  • K04-023 with the temperature gauge aperture

When remapped you should see an easy 250bhp on the stock 1.8T and with other mods the K04 can flow to provide around 300bhp.

When pushing these turbos hard you really should look to upgrade the air intake and intercooler.

Turbos fitted to the 1.8T engine - assume K03 unless listed below but there are some regional exceptions.

  • K03S
    BBU, BE, BJX, BVP, ARY, AUQ, AWV, ARX, AUM, AWP, BEX
  • K04
    BFV, APY, APX, AMK, BAM

An obvious upgrade path for KO3 turbo owners is to swap in a KO4 turbo. The software takes a lot of getting right for the maximum power gains but interestingly most people report that the KO4 turbo runs fine on the standard manufacturer's ECU Map.

It is usually easier to remap the standard KO3 engine and set the boost to 1 bar as per a number of aftermarket Audi tuners standard remaps, then when the K03 gives up on you look to replace it with a better flowing unit like the K04 or a decent hybrid.

The KO4 changes the characteristics of the engine and gives a more rewarding drive pulling hard and when the KO3 starts to run out of steam around 5000 rpm the KO4 still delivers good power so is the logical track day or drag strip turbo.

You may think the KO4 is more prone to lag but this is not the case and both are very similar as far as low down low boost power goes.

A number of aftermarket turbos are available which fit the standard down pipe and they can be tailor made to suit your requirements with many drivers looking for a mix of economy below 2500 rpm and massive power gains from 3000 to 5500rpm.

Differences in KO3/KO3s turbos

The number of blades is the most significant variation between turbos. The K03 has 11 and the K03s has 8.

The actuator that opens the turbine bypass valve is normally a 65N or 85N, however certain versions featured a 2 port actuator. Because 180hp engines run higher boost, they need better quality actuators with larger opening force.

The K03 has the least juice, so with correct add-ons, it can reach 190 horsepower. You may receive more, but the turbo will last less.

The K03s have more power. Most people get 215 horsepower with K03s, which is the safe limit. Exceptionally, and we don't have first hand evidence to back these claims, this turbo has been touted to produce above 250 horsepower, so there is considerable leeway.

This suggests that a K03s gains at least 25 horsepower over a K03 even when run at the accepted safe limits.

K04 Has Superior Performance

Unlike the K03 and K03s, the K04 is bigger and produces much more power especially at the top end of the RPM range.

With suitable upgrades and hardware, the K04's performance can reach 350 horsepower, although the KO4's safe limitations are about 220hp.

(Video) Best A4 Tuning Modifications & Upgrades [Mod Guide]

Size wise The K03 and K03s turbos were smaller. Despite having less power, they took up less room than the K04 when installed, which is why there were installed in so many models across the VAG group range.

Hybrid 1.8 Turbos

Many hybrid turbo manufacturers use a bigger compressor on the intake side to boost power.

Hybrid turbos work really well on the 1.8T, this is where the internals are swapped out to give different blades and blade profiles, and dramatically alters the power delivery and characteristics of the turbo.

We've seen mechanics spending a loads on turbocharger upgrades on the 1.8T only to suffer the indignity of watching the 1.8T literally blow up soon after it's been enthusiastically driven.

Pay attention to the mapping and fuelling and you should be fine. We recommend a rolling road remap is carried out for best results, the off the shelf maps are quite generic and may not fully release your potential power.

A note when choosing turbochargers for your 1.8T Tuning project

Large upgraded turbo units often experience no power at low rpm, and low capacity turbo units spool up much more quickly but don't have the top end power band gains.

the market of turbos is always increasing and we now see variable vane turbos, where the vane profile is altered according to speed to lower lag and increase top end bhp.

Twin scroll turbos divert the exhaust flow into 2 channels and feed these at differently angled vanes in the turbo charger. They also boost the scavenging effect of the engine.

It is common that there's a limit in the air flow sensor AFM/MAF on the 1.8T when loads more air is being drawn into the engine.

We note 4 bar air sensors coping with quite large power gains, whereas the OEM air sensor was restricting power at a much lower level.

The 1.8T N75 valve

The N75 is controlled by the ECU and acts as a bleed valve, it regulated the spool up and boost duration of the turbo.

If your N75 is faulty you'll generally experience lower boost, and or power surging or lumpy power delivery. It may even drop into limp home mode.

Check the N75 valve itself, some faults are actually down to a leak in the vacuum lines.

So what does the N75 do?

You want the turbo to keep spinning but if you lift off the boost produced will just build up, if the turbo shuts down, you'll have to wait for it to spool up. Generally in most cars the wastegate assists the turbo to keep spinning and producing power. The N75 uses the wasted boost to keep the turbo spinning at light load conditions, clever eh? This is why you don't want to fit an atmospheric dump valve, as all that lovely pressurised fast moving air is lost (plus it upsets the ECU and you don't want an upset ECU do you?)

It sits between the wastegate and turbos high pressure outlet, it has 2 outputs and just 1 boost input. The output goes to either the wastegate and the intake (fully diverting boost to the wastegate when it's closed or leaking some boost to the intake allowing for a faster spool up).

The top of the N75 is a small screw, in some cars this has a locked thread to prevent tampering. But if you're lucky you won't be thread locked and can make adjustments to it.

You only need to make very small adjustments to make a difference, and you need to bear in mind the ECU is expecting a certain range of performance from it and will go all LIMP on you if you get it wrong.

Setting the N75 valve right is a bit of an art but adjust it to the right and very little air will be vented from the wastegate giving a smoother power delivery but less overall boost.

Turn it to the left you'll get more boost going to the wastegate but you'll notice the power spiking as the N75 closes and opens.

Essentially a performance version allows greater range of control, a faster response and will be less prone to sticking or leaking, all of which can cause problems in your power delivery.

We have heard of people swapping the N75 for an N18 successfully but you'd be better of sourcing a performance version.

Fuelling upgrades on the 1.8T

When you raise the bhp you will need to uprate to the fuel system.

The air intake may need upgrading, typically the sensor housing is enlarged and used with the OEM MAF sensor, but it makes sense to upgrade the MAF sensor if you want to hit higher power levels.

More bhp needs more air and fuel - it's as simple as that.

Audi 1.8T 20v engine tuning guide with advice & tips (6)Most tuners we speak with say to over specify your injectors flow rate.

You won't get more power just adding bigger injectors, but you will hit power limits with other mods fitted if you don't supply enough fuel.

If you have a throttle cable you are usually running the Motronic M3.8 ECU.

Others use a drive by wire system and use the ME7.x version of the ECU note the extra E which means electronic throttle.

(Video) Starters Guide to Audi Modifications [Tuning Guide]

  • M3.8 AEB, AJL, AGU, AJH... Pre 98 cars typically had stock injectors that are rated at 205cc and will top out at 220bhp.
  • ME7.1/7.5 ARZ, AUM, AUQ, APP, APX ...usually have Bosch 315cc injectors and flow well to 235bhp. To ugprade injectors on these the easy option is to get the 386cc injectors from the ME7.9 engines.
  • ME 7.9 BAM, BVF, BBU, BEK, BJX, APY, AMK, APY... and those with the K04 turbos typically had 386cc injectors that top out around 275bhp.

We've seen 1.8T tuners using Calibra yellows, Saab Reds, and others from the Bosch range all of whom provide upgraded injectors, so it's worth asking around.

Your map needs to take the injector profile into account, so fitting a well known unit can save a lot of time and headaches later.

  • Fitting a 315cc injector will take you to around 245bhp
  • Bosch 550cc injectors allow power approaching 350bhp
  • Bosch 630cc injectors will see you hit around 400bhp.

As a rule of thumb add 20% to the flow rate when buying an injector, this takes into account injector deterioration and affords a bit of spare capacity should the engine need more fuel.

1.8T weak spots and problem areas.

Weak spots - the engine oil used in your Audi must be fully synthetic and changed at the correct service intervals (check your owners manual for details but it is typically a long life Audi service of around 24,000* miles or standard service around 9000 miles.

This depends on how the car is driven so if you are are a heavy footed driver or make lots of short journeys on a cold engine the service interval is reduced from these figures).

Use of the wrong type of oil will cause the oil pump to seize due to sludge created in the turbo housing. This causes a catastrophic loss of oil pressure and engine failure and unless you can prove that the correct oil grade was used the warranty is invalidated.

*Audi long life oil is claimed to last for up to 24,000 miles but all other synthetics are only recommended for 9000 miles!

It seems more sensible to change the oil & filter frequently as metal particles can cause damage to the engine as they become suspended in the oil.

We would change the oil annually or at 12,000 miles using Audi long life oil, it will prolong the life of your engine.

The engine takes 3.7 to 4.35 litres (depending on the oil filter and sump used, transverse engines differ to longitudinally mounted ones) of fully synthetic 5w-30 oil (Audi long life oil must conform to VW 504 00 or 507 00 (Castrol SLX long life III is the special Audi approved oil).

Using the wrong oil will almost guarantee you get dangerous sludge build up which will eventually wreck the turbo. NB: Not all oils marked synthetic are true synthetics.

Some users have reported problems with early coil packs but most of these will have been replaced now and newer coil packs do not seem to have any problems.

Fitting a blow off valve or dump valve can cause problems with the engine management as there is a loss of system pressure. There are now VAG friendly partially recirculating dump valves that also recirculate the lost pressure keeping the ECU happy.

The air flow sensor can become soiled particularly if you use a filter that is impregnated with oil. Take off the air flow sensor and clean with a IPA based solvent if you notice any hesitation or problems that can be assigned to a faulty MAF.

Please check out our guide to VAG group turbochargers, and our tuning articles which will help you get the best out of your car projects. Our forums are a great place to go to chat with our members about your projects and swap tips and ideas. Please also check out my new TorqueCars YouTube channel and be sure to subscribe.

Check out my YouTube channel, we're regularly adding new content...

Audi 1.8T 20v engine tuning guide with advice & tips (7)

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FAQs

How to find 1. 8 t engine code? ›

The engine code can be found on the corner of the cylinder head on the cam belt end, on the engine block itself near the cylinder in between cylinders 3 +4 or could be found in your service book.

Is the VW 1.8 t good? ›

One Volkswagen engine consistently appears on 'most reliable' discussions and lists: the 1.8T. Haynes calls the 1.8-liter turbocharged four-cylinder engine the best VW engine. ItStillRuns compares it to the LS small-block V8 in terms of durability and tunability.

Are Audi 1.8 T engines reliable? ›

Volkswagen 1.8t Engine Reliability

You may have some small issues, like the ones listed above, but the 1.8's are very reliable Volkswagen engines. Since the 1.8t has been around for almost 30 years, obviously with multiple modifications, you can trust the reliability of the engine if it is taken care of.

What kind of engine is a 1.8 T? ›

The turbocharged 1.8-liter mill replaced VW's 2.5-liter inline-five engine because it was lighter and more fuel-efficient. The 1.8T makes 170 hp and 184 lb-ft of torque, and is the base engine in the Volkswagen Passat sedan and Beetle. It's also available on the Jetta sedan.

What is My Audi engine code? ›

The engine code is found on the drivers side front on the engine block. You may also find the engine code on a sticker attached to the cylinder head.

What does the 30 mean on Audi? ›

The smaller the number, the less power it has, meaning higher numbers have more power. For each number, there is a range of outputs, so if it's a '30 TFSI' that means it can have between 108bhp and 129bhp, for example. There is then the fuel designation.

Does VW 1.8 t require premium fuel? ›

In simplest terms, no. Volkswagen vehicles do not require premium gas. However, many Volkswagen vehicles, like the 2021 Volkswagen Tiguan and 2020 Volkswagen Jetta, are equipped with turbocharged engines. Turbocharged engines run best when fueled with high octane fuel, which is found in premium gas.

Which VW engine is most reliable? ›

Despite being originally made for Audi vehicles, the EA888 family is well regarded in the VW community. The the Generation 3 version of the 1.8L TSI takes the crown as the best VW engine on the market.

Is the VW 1.8 t an interference engine? ›

The 1.8T Jetta is an interference engine (a.k.a. non-clearance engine). If the Jetta 1.8T timing belt fails, the timing belt system that links the cylinder head, camshafts, and crankshaft no longer run in sync. Close tolerance engine designs allow for the cylinder head valves to hit the top side of the pistons.

Which Audi engine is most reliable? ›

For used Audis with a 1.8T or 2.0T, go with an EA113 or Gen 3 EA888 engine. Because Volkswagen owns Audi, the two brands often share engines. And as with used Volkswagens, the 1.8-liter and 2.0-liter turbocharged four-cylinder engines tend to be the most reliable.

Which Audi is the most reliable? ›

For the most reliable, that title goes to the 2019 Audi Q5 according to Cars.com. The Audi Q5 just went through an upgrade in 2018, so the 2019 features upgraded interior styling and increased performance capabilities!

CarRef Best tuning tips for the VW Audi 1.8T engine. We look at the best mods and upgrades. The 1.8T engine, one of the most reliable and easy to tune engines around. 1.8T engine Tuning

"Audi you make it go so fast?". The most common turbos fitted are the KO3 & KO3s (150-180 bhp) and KO4 (210-240).. A number of aftermarket turbos are available which fit the standard down pipe and they can be tailor made to suit your requirements with many drivers looking for a mix of economy below 2500 rpm and massive power gains from 3000 to 5500.. Weak spots - the engine oil used in your Audi must be fully synthetic and changed at the correct service intervals (check your owners manual for details but it is typically a long life Audi service of around 24,000 miles or standard service around 9000 miles.. Fitting a blow off valve or dump valve can cause problems with the engine management as there is a loss of system pressure.. This article was written by Waynne Smith on TorqueCars, and I appreciate your feedback and suggestions.

"The 1.8T was my first turbo engine, and one of the best."VAG 1.8T 20v Petrol engine as fitted to Volkswagen/SEAT/Audi and Skoda cars: 150-240 bhp from the factory.Let's see what can be done to tune the 1.8T engine, how much potential power you can extract, and which are the best mods for your proje...

The engine codes are (This list is not exhaustive and covers the most popular engines, some engines were only available in selected markets.). Typical stage 3 mods often include: Engine balancing & blueprinting, Twin charging conversions, Crank and Piston upgrades to alter compression, Adding or Upgrading forced induction (turbo/supercharger) with hybrid or twinscroll, Internal engine upgrades (head flowing porting/bigger valves), Competition cam.. Enlarging the ports and ensuring a decent flow through the head really helps the engine breathe, and the 1.8T can handle around 300hp on the stock internals (depending on your engine code) but the head was not designed to cope with these power levels.. A note when choosing turbochargers for your 1.8T Tuning project Large upgraded turbo units often experience no power at low rpm, and low capacity turbo units spool up much more quickly but don't have the top end power band gains.. The engine takes 3.7 to 4.35 litres (depending on the oil filter and sump used, transverse engines differ to longitudinally mounted ones) of fully synthetic 5w-30 oil (Audi long life oil must conform to VW 504 00 or 507 00 (Castrol SLX long life III is the special Audi approved oil).

1.8T Stage 2 Tuning Guide

MAJOR PARTS NEEDED FOR STAGE 2 POWER: FMIC – full performance exhaust – high flow tip – DV – Cold air induction kit. The major fail with 1.8T stage 2 tuning and low power setups is people modifying their cars in a rush or wrong, i.e. by fitting an upgrade front mount intercooler kit to there car (FMICs) to aid the charge cooling when running higher power, but they are using kit with 2” boost pipes which are smaller than the stock intercooler setup and tend to have lots of sharp 90deg bends which means they have gained better cooling effect but reduced the air flow and created a greater pressure drop between the turbo and inlet manifold.. Also for the Stage 2 tuning you have to have a decent cold air induction kit (CAI) Try to get a decent flowing setup with wont suck in hot air from the engine bay, R-Tech can provide a enclosed cold air induction system for £120 fully fitted.. But be very careful when buying tips as there are poor flowing TIPs on ebay these tend to look good but they provide no more air flow effectiveness over the stock factory fitted TIPs.. R-Tech can supply and fit our unique supersize TIPs for £135 all inc, these are the very best flowing TIPs money can buy if your wanting the very best flow from your engine setup.. On the left is a picture of the best flowing TIP vs the R-Tech 70mm Supersize k03 k03s k03 hybrid TIP which has been proven and tested to flow over 310bhp with the k03 hybrid units.

The Volkswagen 1.8T engine is one of the most tunable engines around today. Tuning tips and options for the 1.8T and a look at the best modifications and parts to maximise your power gains.

We have an updated version of this engine tuning article in our Audi section, so please see the updated article for 1.8T Tuning.. A remap on a standard engine will typically yield around 40-50bhp increase, and, with the addition of a higher capacity turbo, a freer flowing intercooler and efficient induction and exhaust design, power gains to around 300bhp-350bhp are possible.. The engine code is found at the top part of the engine near the valve cover on the side etched into the head.. Small Port size head Engine Codes: ADR, AMB, AMU, APT, APU, ARG, ATC, ATW, AWM, AWP, BEA Large Port size Head Engine Codes: Typically 97-99: AEB, AGU, AFY. It is one of the most costly upgrades but provides the best gains.. Typical stage 2 mods often include: Power/Sport clutch, Ported and polished head, fuel pump upgrades, Fast road cam, high flow fuel injector, Fast road camshaft.. Typical stage 3 mods often include: Upgrading forced induction (hybrid turbo or KO4 upgrade), Internal engine upgrades for stronger parts (pistons/head/valves), Competition cam, Engine balancing.. A fast road camshaft is one of the most effective mods you can do on the 1.8T engine, apart from a remap, or turbo upgrade.. A fuel pump will only deliver a finite amount of fuel, so you may need to uprate this if your injectors are demanding more fuel.

Videos

1. VW 1.8t 20v engine build, head porting, exhaust ports.
(Linder Power Systems)
2. Volkswagen/Audi 1.8t Engine Diagnostic & Maintenance Guide (Mk4 Golf, Jetta, New Beetle, Audi TT)
(FCP Euro)
3. Legendary Engines: The VAG 1.8 Turbo 20v - You Won't Believe How Many Cars Used It!
(JayEmm on Cars)
4. How To Flash-Tune Your Audi ECU
(sReed)
5. Audi A4 1.8T Common Problems
(Stuie's Garage)
6. My Process To Find 1.8T Boost Leaks Fast! | & New TIP
(HunterDirection)

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