Definitive Guide to Building The Early 1.8T Engine For High Horsepower

Guide to building your 1.8T 20V engine block

Integrated Engineering's complete guide to avoiding engine block failure

Popular Audi & VW Models that have the 1.8T (1995-2005)

  • MK4 GTI
  • MK4 Jetta GLI
  • B6 A4
  • B5 A4
  • MK1 Audi TT
  • And many more

This in-depth article will educate you on the 1.8T bottom end in stock form, how to upgrade it correctly to meet your performance goals, and what IE has to offer for your build. If you have any further questions feel free to contact us or leave a comment below.

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If you’re looking to upgrade your 1.8T engine, you have come to the right place. Integrated Engineering (IE) offers a large product line spanning 1.8T engines to modern day platforms... Additional guides pertaining to 1.8T cylinder heads or other engines can be found in our engine building guide blog section.

section1
  • Blocks – there are two styles of 1.8T engine blocks, 058 and 06A.

  • 058 blocks are found in vehicles produced from the beginning of production until year 2000.5.

  • Model years 2000.5 and newer use 06A block.

  • Model year 2000 was a split production year so both 06A and 058 blocks are found in that year.

  • 058 blocks have an internal intermediate shaft that that drives the oil pump and use an external water pump driven by an accessory belt.

  • 058 blocks are only found in the early longitudinal Audi B5 A4 and VW B5 Passat.
  • 06A blocks do not have an intermediate shaft and use a water pump driven by the timing belt. The oil pump is chain driven by the oil pump drive gear located on the snout of the crankshaft.

Watch the video below for more information on how to identify you 1.8T block type:

Mains Caps & Bearings

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Like most other VAG 4 cylinder engines, the 1.8T uses 5 two-bolt main caps. There are 4 outer main caps and one center main cap that contains crankshaft thrust bearings (also commonly called thrust washers). The stock main caps are cast iron and can be upgraded to IE's billet steel versions as power output increases.

The block side of the main caps have M10 threads but the lengths between 06A and 058 vary as noted below:

Crankshaft

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All 1.8T stock cranks have a stroke of 86.4mm.  Cranks found in the 06A can be found forged or cast iron. Most 058 crankshafts are cast iron. The timing belt drive gear and crankshaft damper is attached via a 4 bolt interface. Also on the crankshaft is the trigger wheel which is used in part with the crank sensor to determine engine RPM.

  • 06A blocks use a slotted style trigger wheel.

  • 058 blocks use a dented style trigger wheel.

Rods & Bearings

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All 1.8T connecting rods measure 144mm on the center-to-center dimension and have a big-end journal width of 24.90mm. With the common measurements out of the way, that leaves the wrist pin size, which vary depending on engine codes.

  • Most 06A 1.8T engines employ a 19mm wrist pin (225 horsepower models use 20mm).

  • 058 1.8T engines typically use a 20mm wrist pin.

Pistons

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Some 1.8T pistons are cast rather than forged, which results in a fairly weak piston. Some engine codes did have forged pistons but they are not designed for high power levels, and still not as robust as forged aftermarket pistons.

  • All stock 1.8T pistons have a bore size of 81mm.

  • Factory published compression ratios tend to vary but from our experience actual compression ratios range from 9.25:1 to 9.3:1.

section2

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This section will be separated by different horsepower levels. Our goal is to point you in the right direction and make your build a success.

300ug

300HP+ Connecting Rod & Piston Upgrades

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At 300+ hp we often recommend using a set of IE connecting rods with stock pistons. This proven combination works fine as long as the piston skirts and cylinder walls are in good shape. In high mileage or worn blocks,  larger bore aftermarket pistons should be used so piston-to-wall clearances can be set correctly. It is fairly common knowledge at this point that 1.8T connecting rods are the weak point in the bottom end, since they were designed for only 150-225HP depending on the model.

Two main factory connecting rod weaknesses:

  • Very narrow beam design that leads to bent rods under increased torque.

  • Inferior metals (stock rods are usually made from sintered iron) compared to aftermarket forged rods.  These weak alloys lead to broken connecting rod beams.

There are two possible solutions if you are planning on using upgraded rods with stock pistons connecting rod options:

  • 06A blocks will typically require 144x19mm connecting rods that have a tapered wrist pin (with the exception of 225hp engines). There are many engine codes that accept these rods with stock pistons. (availabe with rifle drilling) IE part numbers: IERHVA2, IERHVA2-RD

  •  058 blocks or other high-output (225 HP) 1.8T engines will typically require 144x20mm connecting rods to be used stock pistons.  Common engine codes that use 20mm wrist pins are AEB, AGU, AMK, AMU, APX, ATC, ATW, AWD, AYP, and BEA. (available with rifle drilling) IE part numbers IERHVA1, IERHVA1-RD

Connecting Rod Rifle Drilling

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Rifle drilling is an oiling hole that travels the length of the connecting rod beam from the big end to the small end of the connecting rod. Additional pin oiling has been shown to greatly extend bushing life on daily driven or high mileage applications.

300HP+ Engine Hardware

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At these power levels the stock hardware, such as main bolts, are adequate. One important fact that enthusiasts often overlook however is that many stock bolts are stretch bolts and thus are one-time use only.  Stated another way, once the bolts are removed from your engine, they must be replaced with new/unused units.

Common OE bottom end hardware that are one time use and should be replaced are:

  • Flywheel bolts (6)

  • Crank damper pulley to timing gear bolts (4)

400ug

400-500HP Connecting Rod Upgrades

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To ensure reliable operation at power levels exceeding 400HP upgrading to aftermarket pistons and rods is absolutely necessary.  All 1.8T aftermarket piston & rod combinations offered by IE use a non-tapered 144x20mm connecting rod with a matching 20mm aftermarket piston.

  • H-beam 144x20- Proven strong and reliable IE Part Number: IERHVA1

  • H-Beam 144x20 rifle drilled- strong and reliable with added wrist pin longevity from rifle drilling IE Part Number: IERHVA1-RD

  • Tuscan I-beam 144x20- our highest quality connecting rod: strong and reliable, superior strength-to-weight ratio, included rifle drilling for wrist pin longevity IE Part Number: IERTVA1

400-500HP Piston Upgrades

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  • Mahle pistons- a great option for street builds and daily drivers, quiet piston operation, tight piston-to-wall clearances due to low expansion alloy. Explore pistons

  • JE pistons- a great option for street or track use, uses a tough 2618 alloy piston forging, with tons of compression ratios and bore sizes available. Explore pistons

  • Wiseco pistons- a great option for street or track use, affordable yet good quality, uses a tough 2618 alloy piston forging. Explore pistons

400-500HP Crankshaft Timing Gear Interface

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The 1.8T timing belt system is a major weak point. The most common failure point is the timing gear located on the snout of the crankshaft. As a solution, we have developed a crankshaft timing gear that is far stronger than the original unit and also an ARP crank bolt that increases the amount of force holding the gear on.

For 06A applications, we offer a press-fit timing gear along with an IE Spec ARP crank bolt.

For 058 applications, we offer a dowel-pinned OEM timing gear, along with an IE Spec ARP crank bolt.

  • IE dowel pin kit (This kit allows you to drill and ream a hole in the end of the crankshaft, which allows a hardened steel pin to be installed) IE Part Number: IEBEVA6

400-500HP Engine Bearings

1.8tenginebearings400500hp

We highly recommend using a performance main bearing and rod bearing as power levels increase. The main advantage of performance bearings is due to a tri-metal composition they are able to withstand added bearing loads and are better suited to withstand crankshaft flex.

400-500HP Engine Hardware

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At this power level, the stock hardware is typically sufficient as long as it is never reused. If you plan on pushing the car further in the future you may want to consider to upgrading to ARP engine hardware. As an added bonus, ARP hardware is reusable and does not need to be replaced if removed.

1.8T 06A ARP Hardware:

1.8T 058 ARP Hardware:

Also, be sure to check out our complete ARP hardware kits for 06A and 058 engines.

400-500HP Main Cap Upgrades

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The stock main caps are cast and lack the rigidity required for a reliable high powered build. As an upgrade we offer billet steel main caps that are far more rigid and will help to reduce main bearing wear. Be sure to check that your machine shop can align bore and hone mains before ordering.

500ug

500HP+ Connecting Rod Upgrades

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    • H-beam 144x20- Proven strong and reliable IE Part Number: IERHVA1

    • H-Beam 144x20 rifle drilled- strong and reliable with added wrist pin longevity from rifle drilling IE Part Number: IERHVA1-RD

    • Tuscan I-beam 144x20- our highest quality connecting rod: strong and reliable, superior strength-to-weight ratio, included rifle drilling for wrist pin longevity IE Part Number: IERTVA1

500HP+ Piston Upgrades

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  • Mahle pistons - standard Mahle shelf pistons unfortunately come with fairly weak wrist pins in most 1.8T applications. At this power level, you should consider using our 1.8T Mahle Stroker custom pistons, which include a very stout wrist pin. Explore pistons

  • JE pistons -a great option for street or track use, manufactured from tough 2618 alloy piston forgings. Tons of compression ratios and bore sizes available. Explore pistons

JE 1.8T Custom Spec Pistons

 

Integrated Engineering knows these motors inside and out, we can help determine the custom specifications to design the exact piston to meet your project's goals. Contact sales@performancebyie.com to order custom spec pistons

  • Any bore, compression ratio, and several crankshaft strokes available.

  • Thermal dome coating - reflects heat away from the piston. Commonly used in high HP turbo builds or nitrous applications.

  • Anti-friction skirt coating -  Commonly used in endurance applications to increase piston skirt longevity.

  • Oil-shed coating - used to minimize rotating assembly weight, generally in high RPM naturally aspirated applications.

  • Upgraded wrist pins - options range from small and lightweight to stout and strong for turbo high HP turbo builds.

  • Lateral gas ports - ensures superior piston ring seal by increasing gas pressure behind the rings. Only recommend for race use as lateral gas ports generally become clogged quickly and wear rings quickly in street applications.

500HP+ Crankshaft Options

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Some stock 1.8T crankshafts are made from cast iron. At a certain point, it is a good idea to upgrade to a forged crankshaft. For that reason, many serious 1.8T builds use a forged 2.0L crank to convert the 1.8L block into a 2008cc 2.0L stroker engine. (Requires stroker pistons)

  • 2.0T FSI 92.8mm Stroker Crankshaft -This factory forged 2.0 FSI crankshaft is modified with a special IE oil pump drive gear which makes it a drop in 2008cc crankshaft for 06A blocks. IE Part Number: IESKVA6

500HP+ Crank Damper Options

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At this power level using a crankshaft damper such as Fluidampr can increase main bearing life by absorbing crankshaft vibrations. We generally recommend one of the two following options. 06A block only

If you do not already own any 4 bolt components we would recommend using the following 6 bolt components for added security at no extra cost.

500HP+ Main Caps & Girdle Plate Upgrades

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At this point the main caps should be upgraded at minimum to prevent excessive main bearing wear. As power levels increase you should consider using billet main caps and a main bearing girdle kit.

  • IE 06A standard main caps & IE girdle kit - Standard main caps are the simpler solution as they use spacers on the top of main caps. The spacers are then machined to form a level oil pan surface that the girdle plate will sit on. IE Part Number: IEBEVA9

  • IE 06A tallboy main caps & IE girdle kit - Tallboy main caps, an Integrated Engineering innovation, require complex machining to be installed installed. Instead of using spacers on top of the main caps, the main caps stand proud of the deck and then must be machined flat. In the end they are the better solution as they provide a more stable, and flat, mounting surface for the girdle plate. IE Part Number: IEBEVA13

  • IE 058 standard main caps & IE girdle kit - Standard main caps are the simpler solution as they use spacers on the top of main caps. The spacers are then machined to form a level oil pan surface that the girdle plate will sit on. IE Part Number: IEBEVA12
  • IE 058 tallboy main caps & IE girdle kit - Tallboy main caps, an Integrated Engineering innovation, require complex machining to be installed installed. Instead of using spacers on top of the main caps, the main caps stand proud of the deck and then must be machined flat. In the end they are the better solution as they provide a more stable, and flat, mounting surface for the girdle plate. IE Part Number: IEBEVA14

500HP+ Crankshaft Timing Gear Interface

18timingface500hp The 1.8T timing belt system is a major weak point. The most common failure point is the timing gear located on the snout of the crankshaft. As a solution we have developed a crankshaft timing gear that is far stronger than the original unit and also an ARP crank bolt that increases the amount of force holding the gear on.

For 06A applications, we offer a press-fit timing gear along with an IE Spec ARP crank bolt.

For 058 applications, we offer a dowel-pinned OEM timing gear, along with an IE Spec ARP crank bolt.

  • IE dowel pin kit (This kit allows you to drill and ream a hole in the end of the crankshaft, which allows a hardened steel pin to be installed) IE Part Number: IEBEVA6

500HP+ Wrist Pin Upgrades

18twristpins500hp

Why did we create a section just about wrist pins? We have seen endless builds fail due to under spec’d wrist pins. Many piston manufacturers use a lighter spec pin that works for lower horsepower builds, however with higher HP levels and raised cylinder pressures you need a stronger wrist pin. For any build using JE pistons, we recommend upgrading to the tool steel wrist pins. Be sure to always check the material specifications and wrist pin wall thickness to avoid any pin failures!

500HP+ Engine Bearings

18tenginebearings500hp

We highly recommend using a performance main bearing and rod bearing as power levels increase. The main advantage of performance bearings is due to a tri-metal composition they are able to withstand added bearing loads and are better suited to withstand crankshaft flex.

500HP+ Engine Hardware

18thardware500hp

At this power level, the stock hardware is no longer sufficient. With the increased levels of load, it is very highly recommended to upgrade to ARP engine hardware. As an added bonus, ARP hardware is reusable and does not need to be replaced if removed.

1.8T 06A ARP Hardware:

1.8T 058 ARP Hardware:

Also, be sure to check out our complete ARP hardware kits for 06A and 058 engines.

This concludes our overview on building a 1.8T 20V bottom end. If you have any further questions, please contact us or leave a comment below. Thanks for reading!

58 thoughts on “Definitive Guide to Building The Early 1.8T Engine For High Horsepower”

  • Great write up! Wish this was around 5 years ago. So many questions answered here.

    Reply
  • Is there anything like this to do with Nissan Micra's K11 2001 engine's preferablely something for a 1.0 or 1.3

    Reply
  • Hello integrated engineering

    I would to ask you I have beetle millennium cup edition 1.8 engine while turbo AVC code engine, can I upgrade this engine

    Thanks

    Reply
    • Integrated Engineering May 18, 2016 at 9:20 am

      Hi there! Yes, all these engine parts should be applicable to your special edition 1.8T 20V.

      Reply
  • Hello

    I'm not building a 1.8t as yet but thank you for the info.

    What I need to know is:

    Does IE stock stroker kits for the 06A 2l 20v conversion?
    That's what I've got at the moment.
    Built by VW motorsport South Africa.
    It made 145kw.
    After subtle modifications I got it up to 166.8kw.
    Now. . .
    High compression pistons, high duration and lift Camshafts are the main items I am looking for.
    The aim is to build a 200kw n/a high compression engine.
    Thanks in advance.

    Reply
    • Integrated Engineering May 18, 2016 at 9:18 am

      Hi there! Yes, we stock and sell several 2L/1.8T stroker kits. We are going to publish a stroker kit article shortly. We removed it from this article in fact because it was already quite long. Keep your eyes peeled for it. Thanks.

      Reply
  • This is awesome information since I will soon be building my 1.8t passat 4motion. Please send any information on cylinder head recommendations as I want to install a stage 3 kit from APR. Thanks in advance.

    Reply
  • I would like to build or have built a 350bhp AUQ engine. Is that possible? and how much would I be looking at £££ in parts

    Reply
    • Integrated Engineering May 18, 2016 at 9:14 am

      Hi there, that is a very reasonable request. Send us an email to sales@performancebyie.com and we'd love to help you. Thanks!

      Reply
  • Hi i have a 1.8t jetta with a aww. K04 turbo and im looking to build the motor. How much wouls it be to shoot for 400hp? Im running 22psi of boost right now

    Reply
    • Integrated Engineering May 31, 2016 at 10:22 am

      A link to all the products recommended for 400HP is in the 400HP section, if you would like more help putting together a build our sales team will happily help you. Contact them at sales@performancebyie.com
      Thanks!

      Reply
  • Hello, I really liked this article, it had a lot of good information and answered alot of my questions about the 1.8t's, so thank you for that.

    My question is that what if you wanted to make a lot of horsepower? Such as 900? Could it be done with the 1.8t?

    Reply
  • Hi, while looking at parts for my 02 wolfsburg jetta, it dawned upon me that nobody has attempted to create a hemi head for really any I4 or V6 engines. It is in my belief that paired with the 2.0l stroker kit one would possibly experience higher power gains at lower a lower rpm with big turbo set ups due to the further increaced capacity due to the hemispherical shape of the combustion chamber. Would it aid in gaining power or be a hinderance? If it would help, what could the gains be? And if it worked well, would Integrated Engineering consider producing it? Just food for thought, thanks!

    Reply
  • Hi there

    I'm wondering if you may have any advice about my idea to pull the engine out of my 1.6 polo 6R. It seems that the 1.8T 20V is the right motor. I don't know much at all and would appreciate a bit of advice about installing the motor and creating the right set up for my car. Engine mountings, wiring harness etc.

    Thanks

    Reply
  • Hi there

    I'd like some advice on my idea of pulling my standard 1.6 motor out of my polo 6R and fitting the 1.8T 20V. Will it be a pain in the rear or will it be worth my while. I don't know much, so any advice will help

    Thanks

    Reply
  • Hi IE

    Would you shoot me an email if you have any direct suppliers in the UK, and any recommended garages that would be able to rebuilt an engine with your parts. It's hard to find reputable mechanics these days.

    Reply
    • Integrated Engineering October 7, 2016 at 12:50 pm

      Hi AJ,
      Thanks for contacting us!

      Performance Powertrain Solutions LTD is now our exclusive authorized Integrated Engineering product importer/distributor for the UK. Performance Powertrain has made the necessary commitment to our company in order to become our sole importer for the UK market.

      PPT now acts as IE for all of our UK customers and can quickly and easily supply any IE part directly to you from them and even answer any questions you may have.

      You may contact Performance Powertrain Solutions LTD at: sales@performance-powertrain.com or ryan@performance-powertrain.com

      Performance Powertrain Solutions LTD
      72-82 Belgrave Road
      Portswood Southampton SO173AN
      UNITED KINGDOM
      023 8115 7997

      They can assist you with all of your IE product questions and purchase needs. Performance Powertrain Solutions LTD and staff will take very good care of you and all of our UK customers.

      Reply
      • Grayson A Rhea July 27, 2018 at 4:57 pm

        I have purchased a 2017 V W Passat S with a 1.8 I am looking for someone that could build me a awesome engine, money is definitely not a problem as I have a nice supply, I just need someone I can trust to build me a very high quality project... Please let me know ASAP... Thank Grayson.

        Reply
        • We would be happy to help! Give our sales team an email and they will get you taken care of no problem: sales@performancebyie.com

          Reply
  • Hey there! I have an audi TT with the atc engine, unfortunately its the non quattro version. I understand that the awd version of the TT is not a true quattro tho. Would you reccomend getting a 225 quattro to modify? Thank you so much!

    Reply
  • Are there any rods and pistons using stronger 22mm wrist pins in order to avoid failure?For example for newer tsi engines 23mm pins are available..

    Reply
    • Integrated Engineering February 24, 2017 at 11:34 pm

      Hi there, at the moment the only rods we offer for the old 1.8T use 20mm wrist pins. Unless you are planning on exceeding 800-1000HP there's really no reason for a big as big a 22mm. Just be sure to use a very high quality wrist pin.

      Reply
  • I have an 02 GTI that I've always wanted to do something crazy with. It's currently not being driven so I have the luxury of time.

    What type of parts cost am I looking at to do the 300 to 400 hp build? My main focus is to have a very derivable sleeper.

    Thanks

    Reply
  • Hey, I'm looking to build the 1.8/2.0 stroker and looking to get the 83mm forged pistons. What do I tell my machinist to bore the block to will it be 83mm exactly? Is the tolerances built in the piston?

    Reply
  • Hi, I have a 1.8T Awt from a Passat, I want to get 83mm pistons with IE 144x20mm rods. Do I need to change my crank or the stock one can take de 20mm rods?

    Reply
    • Integrated Engineering May 9, 2017 at 11:41 am

      You only need to change the crank if you are looking to use stroker pistons. If you do not want to stroke it with a new crank, then you do not need 83mm pistons either. 81.5mm or 82mm pistons should be just fine for stock stroke builds. 144X20 rods are perfect for both stock and stroker crank builds using 20mm aftermarket pistons.

      Reply
  • Hey, love the write up. quick question tho. could you change lets say a AWU engine head and swap it with a BAM to improve on power while keeping the main block the same?

    Reply
    • Integrated Engineering May 9, 2017 at 11:38 am

      Hey Dan,
      Depends on your size of turbo. Swapping to a large port head could dramatically help increase power, but only if you are pushing the boost on the top end to need it. Keep in mind, whenever you increase flow such as large rport head, manifold, throttle, cams, etc... you risk sacrificing the low end to gain top end power. SO if you are on a smaller frame turbo, you may add lag and not benefit from the top end by swapping to a larger port cylinder head such as the AEB.

      Reply
  • Hello, I'm doing a Mk6 2.0l 8v to 20v swap and I was wondering if any block honing was required with 83mm pistons? Also, I acquired an 058 AEB head and was wondering what modifications are needed for the cam follower.

    Reply
    • Integrated Engineering June 16, 2017 at 4:21 pm

      Hey Isiah,
      he stock bore of a 1.8T is 81mm, so if you plan to install 83mm pistons then yes, you will need to bore and hone the cylinders for 83mm. If you swap to a 20V head, there is no cam follower. The 1.8T 20V is not a HPFP system, so there is no high pressure fuel pump or cam follower on that head.

      Hope that helps!
      -Tyler@IE

      Reply
  • daniel salloum May 24, 2017 at 8:40 am

    hi ,
    just want to send my 058 block to machine shop but i just want to make sure if the piston to wall clearance with Mahle piston 83 mm are the same as JE pistons due to the low expansion piston and what are made from , and any clearance specs should be take it ?
    thank you

    Reply
  • is very infomative

    Reply
  • The pistons used here in this blog is it pos to buy a set of these pistons 82.5 8.5:1 compression and my I have part number for these please
    Thank u if u can help

    Steve @ AMD TUNING ESSEX

    Reply
    • Integrated Engineering July 27, 2017 at 10:47 am

      Hey Steve,
      Send our sales team a message for help on piston options: sales@performancebyie.com

      Thanks! -IE

      Reply
  • Hi there, I've currently got a mk1 seat leon fr 1.8t AUQ. Unfortunately my bottom end has blown and my garage has said it's a full engine rebuild or engine replacement.
    I've found another engine and the garage are fitting for me, but as my old engine has only covered 87,000 miles I'm going to keep it and have a go at stripping it and rebuilding it myself as it's something I've always wanted to do.
    Only problem is I have absolutely no idea how lol.
    I was wondering if you have a guide for beginners on how to rebuild from scratch with upgrades to create an engine for the track.
    Thanks in advance
    Ash

    Reply
  • im in Australia we seem to have not much here like ur business its amazing i have mk4 gti im about to buy new head for it cause cant get one in Australia was thinking about doing bottom end want to make good power out of my gt35 turbo or my t70 what do u think

    Reply
  • This article is exactly what I was looking for. Sure sounds like you know this engine and what you're talking about.
    My Turbo S is getting a little tired and needs more then a Krylon rebuild. I will be referencing this article and in contact to assure the rebuild won't be scattered on the street somewhere

    Reply
  • Great article. I'll be in contact.

    Reply
  • What can the 1.8t AWP be bored to.

    Reply
  • hello
    can i mod my Audi A4 1.8t Quattro tha have the AJL eng thanks

    Reply
  • Paul Andrew Townsend August 6, 2018 at 10:52 am

    hi , what a fantastic read , im in process of tuning with bolt on goods an auq engine, my tuner recons it should safetly go to 250-60 ish , its got 630cc injectors and a t3/t4 turbo refurb by turbo dynamics ,no doubt I will want more ,what can you guys recommend for a safe 350 -400 bhp ,and if possible can you give some rough price for the parts ,I have a local oldl boy engineer who can bore and drill anything ,regards paul t.

    Reply
  • I have 2004 Audi A4 1.8 turbo FWD Ultra sport manual what kind block is it ? 058 or 06A ?

    Reply
  • Hi, is there a link you have to purchase the 500+hp kit? Thank you

    Reply
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