VW golf3 AEE engine Turbo project
03-11-2008, 08:32 PM
#1
0.5 BAR
Thread Starter
Join Date: Aug 2005
Posts: 187
VW golf3 AEE engine Turbo project
Finally its time...
Plan: Turbocharged vw Golf 3 with a little extra Nm
I dont use the most common engine for boosting a VW (a g60 engine), but an AEE engine. The engine is also in a Golf3 uit 1996, skoda octavia, polo, and som other german cars.
I was driving my D16z2 turbo with a friend of mine who sat on the passengers seat. When he got out of the car he was in a state of shok
... so he wanted BOOST
The car
ALL STOCK ! STOCK STOCK STOCK STOCK STOCK STOCK
Searching the ECU, and then see whats next..
I guess the interieurfilter has never been changed. Seems like there is an 100 year old tree living in this car, There were somany leaves under the filter, it took almost 1 vacuumcleaner bag to clean the mess..
Aircleanerunit and battery taken out.
F(*&@#$!cking small throttlebody45mm. A G60 Throttlebody will replace it, but it wont fit the intakemanifold, so i need to custombuild one... The g60 is nesseary becaus it has a WOT switch, and the AEE throttle has a TPS the G60 throttle has 2 throttlebodies 1 bigone 54mm, and a small one. you can do the math 
Wire harnas from the enginebay, and the intakemanifold
A g60 wireharnas will replace the original wireharnas
I noticed an wierd nipple on the fuelrail. Its mounted on the intakemanifold, and there it closes, seems quite useless.. I wonder why its there??
The flange needs to be copied... there is no gasket, only rubber rings.. So ill use KIT or DIY gasket.
Dont wanna do mesurements, I did it ghettostyle.. A piece of paper. hold it tight, and gave it a rub with dirty hands and the result was an exact copy.
Starting with the flange. its 7 or 8 mm iron. Just drilling the holes and next is to use a ( i dont know the english word), My garage doesnt have a whole-drill or whatever its called.. ( to drill 32mm hole0s).
Afther a while the
got fucked up... So i told my collegue to buy a hole-drill set.
Now i gotta wait till i get the drill set.
Plan: Turbocharged vw Golf 3 with a little extra Nm
I dont use the most common engine for boosting a VW (a g60 engine), but an AEE engine. The engine is also in a Golf3 uit 1996, skoda octavia, polo, and som other german cars.
I was driving my D16z2 turbo with a friend of mine who sat on the passengers seat. When he got out of the car he was in a state of shok
... so he wanted BOOST The car
ALL STOCK ! STOCK STOCK STOCK STOCK STOCK STOCK
Searching the ECU, and then see whats next..
I guess the interieurfilter has never been changed. Seems like there is an 100 year old tree living in this car, There were somany leaves under the filter, it took almost 1 vacuumcleaner bag to clean the mess..
Aircleanerunit and battery taken out.
F(*&@#$!cking small throttlebody
45mm. A G60 Throttlebody will replace it, but it wont fit the intakemanifold, so i need to custombuild one... The g60 is nesseary becaus it has a WOT switch, and the AEE throttle has a TPS the G60 throttle has 2 throttlebodies 1 bigone 54mm, and a small one. you can do the math Wire harnas from the enginebay, and the intakemanifold
A g60 wireharnas will replace the original wireharnas
I noticed an wierd nipple on the fuelrail. Its mounted on the intakemanifold, and there it closes, seems quite useless.. I wonder why its there??
The flange needs to be copied... there is no gasket, only rubber rings.. So ill use KIT or DIY gasket.
Dont wanna do mesurements, I did it ghettostyle.. A piece of paper. hold it tight, and gave it a rub with dirty hands and the result was an exact copy.
Starting with the flange. its 7 or 8 mm iron. Just drilling the holes and next is to use a ( i dont know the english word), My garage doesnt have a whole-drill or whatever its called.. ( to drill 32mm hole0s).
Afther a while the
got fucked up... So i told my collegue to buy a hole-drill set.Now i gotta wait till i get the drill set.
03-11-2008, 08:43 PM
#2
0.5 BAR
Thread Starter
Join Date: Aug 2005
Posts: 187
Re: VW golf3 AEE engine Turbo project
Gotta show some goodies 
The external wastegatefinally arrived. the internal spring is rated @ 6.9 psi i didnt tested it yet, but ill do that soon.
here some pics. the WG came with a screamer pipe, and some flanges. and that for only 100 euro + 13 shipping. its ------- cheap.. in the netherlands its almost impossible to buy 1 for 200 euro. I was lucky and bought this 1 from a tuner in belgium.
Some turbo's i have got. an IHI RHb5 @ 1,2 bar.
an ihi from a subaru lagacy twinturbo,
a Garret .48 turbo.
Green injectors from a G60
Olie adapter.
external WG with all the bells and horns...
38 mm valve.
bottom pic
The external wastegatefinally arrived. the internal spring is rated @ 6.9 psi i didnt tested it yet, but ill do that soon.
here some pics. the WG came with a screamer pipe, and some flanges. and that for only 100 euro + 13 shipping. its ------- cheap.. in the netherlands its almost impossible to buy 1 for 200 euro. I was lucky and bought this 1 from a tuner in belgium.
Some turbo's i have got. an IHI RHb5 @ 1,2 bar.
an ihi from a subaru lagacy twinturbo,
a Garret .48 turbo.
Green injectors from a G60
Olie adapter.
external WG with all the bells and horns...
38 mm valve.
bottom pic
03-12-2008, 08:36 AM
#6
0.5 BAR
Thread Starter
Join Date: Aug 2005
Posts: 187
Re: VW golf3 AEE engine Turbo project
Its the stock transmission. i dont know if its cableshift or shiftlinkage (020). Actually i dont even know what shiftlinkage means you mean shifting connected with bars? so not hydraulic or cable?
you mean shifting connected with bars? so not hydraulic or cable?
03-12-2008, 09:55 PM
#7
0.5 BAR
Join Date: Jul 2007
Posts: 155
Re: VW golf3 AEE engine Turbo project
yup, it would be bars and such wich would be a 020 if its cable i think its an 02A, just wondering since i've heard the 020 doesnt like boost, the 02A is a better platform, i'm running the 020, i've just never seen the motor your buidling so just curious what tranny it mates to
03-12-2008, 10:27 PM
#8
3.0 BAR
Join Date: Dec 2005
Posts: 2,081
Re: VW golf3 AEE engine Turbo project
What are you doing for engine management? What ecu is that? digifont? G60 throttle body does have 2 plates in it and 2 seperate holes but one is for the return to the supercharger, and only opens when the main throttle plate is closed, unless there is some mod you need to do to it fill us in. I hate vw's with a passion but one of my friends has a g60, we have NO tuning options besides a standalone unless I can get ahold of a rom editor for the digifont. come on spill the beans!
03-14-2008, 07:40 AM
#9
0.5 BAR
Thread Starter
Join Date: Aug 2005
Posts: 187
Re: VW golf3 AEE engine Turbo project
I'll chek the transmission code.
this is what i did yesterday
Drilled the holes, marked the surroundings.
equalized it with a grinder
4 flanges... took a whole ------- day ! ( with some crap stuf interrupting me all the time)
engine management = G60 ECU
the g60 ecu can see boost till 1,2 bar. this setup will be 7 psi.
I know the throttlebody is differnt. I will clsoe the return one, with dead-end tube. (maybe this is were I'll mount the bov.)
I also hate VW with a passion. No high rpms and No power No tuning capabilitys so thats gay!, and on top of that, its gay anyway!
this is what i did yesterday
Drilled the holes, marked the surroundings.
equalized it with a grinder
4 flanges... took a whole ------- day ! ( with some crap stuf interrupting me all the time)
engine management = G60 ECU
the g60 ecu can see boost till 1,2 bar. this setup will be 7 psi.
I know the throttlebody is differnt. I will clsoe the return one, with dead-end tube. (maybe this is were I'll mount the bov.)
I also hate VW with a passion. No high rpms and No power No tuning capabilitys so thats gay!, and on top of that, its gay anyway!
