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2003 VW GTI - Project Silverstone Engine Overhaul Part 6

034Motorsport has almost finished our 1.8T big-turbo project

Jun 3, 2011
Eurp 1106 01+project silverstone engine overhaul+cover.JPG Photo 1/6   |   2003 VW GTI - Project Silverstone Engine Overhaul Part 6

We apologize for not having an update on Project Silverstone last month. As you may know, modifying cars rarely goes according to plan!

This isn’t to say we had a major issue with our ’03 VW GTI, but some tasks take longer than expected. After all, perfection takes time and we want the best for our cars.

2015 Volkswagen GTI
$24,785 Base Model (MSRP) 25/34 MPG Fuel Economy

For the last five weeks, the car’s been in the care of 034Motorsport in Fremont, CA. They’ve been developing a new transverse 1.8T turbo kit, using Silverstone as a test mule.

When finished, the kit will fit all Mk4 Golf, GTI and Jetta 1.8T, as well as the Audi TT. Don’t get us wrong, there are already big-turbo kits on the market but we liked what 034 had planned. Instead of utilizing a top-mount location, exposing the turbo in the engine bay, they wanted to design a stealth package that retains the factory turbo location close to the firewall. This way, if somebody asks you to open the hood, everything looks normal…

In et 4/11, we previewed the major components for the kit – a Garrett GT2871R turbo and 034’s high-nickel content cast manifold. The turbo is a dual ball-bearing eliminator-style unit that features an internal wastegate and is much larger than the factory K03. The manifold showcases a long-runner design for optimum flow but is engineered to look OEM.

With the parts temporarily bolted to the engine, 034 noticed the heater core caused clearance problems. The plastic plumbing would need to be cut and re-routed in order to make room for the turbo – no easy job since the intake manifold had to be removed for access. Then, 034 trimmed one of the lines and are in the process of creating a durable silicone hose set as a replacement for the rest of the lines.

Eurp 1106 02+project silverstone engine overhaul+engine.JPG Photo 2/6   |   As you can see, 034’s manifold keeps the turbo hidde

Another hurdle was the brake lines below the air intake. A line protruded about 2" too far, preventing the turbo from mounting properly. So 034 sourced a banjo fitting to make it shorter.

With these barriers gone, the intake pipe and exhaust downpipe were next. 034 fabricated a 3" inlet pipe from aluminum that’s considerably larger than our original Samco part. While the piece in our kit is metal, the production part will be constructed from silicone.

The inlet pipe will mate to a larger MAF housing from the 225hp Audi TT. The MAF itself will bolt to the airbox and we have the option of retaining our cold-air intake or going back to the factory airbox. For stealth purposes, we’ll probably revert to the stock airbox…

034 designed the kit so you can retain the existing downpipe. Since we had a Techtonics 2.25" downpipe, 034’s new adapter will allow it to mate to the turbo. The flanges for the adapter were being machined during our visit, so we’ll show you these next time.

Once all the mechanical elements are finalized and bolted up, 034 will be putting everything into production and together we will address the fueling and tuning.

Stroked 2.0L
Although this is our sixth update for Project Silverstone since et 12/10, don’t be alarmed if you missed an issue. Each one can be found online at

Our GTI started at Raven Motorsport where we disassembled the motor and rebuilt the bottom-end with a two-liter stroker kit from Integrated Engineering. From there, 034 got us ready for more power with an AEB head updated with enlarged ports, oversized valves and an Autotech intake cam.

Eurp 1106 03+project silverstone engine overhaul+intake.JPG Photo 3/6   |   For more airflow, 3

When the motor was finished, we drove to 034 to set a baseline dyno of 203.8whp. To read up on Project Silverstone, visit


Integrated Engineering
Raven Motorsports


Fremont, CA 94539
Integrated Engineering
Salt Lake City, UT 84115
Raven Motorsports
Long Beach, CA 90813
Sam Du
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