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THE OFFICIAL X-FLOW SWAP POST!!!!!!

550K views 2K replies 370 participants last post by  syncrogti 
#1 ·
There are alot of vortexers looking for info on the X-Flow swap. I was in the same boat before doing mine, so I've decided to make an offfical detailed post about it.
Here is the basic info of what I started with.
1995 OBD1 X-Flow motor (no doner car) $200
The motor was basic no alternator or tensioners.I had to buy/borrow/ and steal alot of parts. go with the buy and borrow methods if your not confident in your ability to steal

What I needed
Alternator (Must be A3) $200
power steering pump and bracket (MUST BE OFF OF AN A3) $20
Water pump bracket (MUST BE A3) $Free
A/C Delete pully (I ditched the A/C) $16
MAF ($50 for both Coil, and MAF)
Coil
New spark plug wires (A2 wirers wont work) $78
Wire harness (engine and fuel rail) get the VAG harness if you can but its not necessary. $150
Gaskets (might as well)
38 inch V belt for the alternator. If you do the A/C delete use this belt! It wont fit exactly but it will stretch on. 38.5 will fit good for about 4 days then it will touch, put the 38 on and let it stretch. beleive me I have 60 dollars worth of belts in my car that I have to return. $20
ECU Stolen (sorry ma!)
General notes
Radiator: You can use the stock radiator with this setup. eliminate the long tube from the overflow bulb to the upper radiator and get the one from the A3 that goes from the back of the block to the overflow bulb. simply cap off the open end on the radiator
Buy a clutch: You might as well go ahead and do this while its out. get a flywheel too if you can I bought mine from qualityvwparts.com. I love it!
wiring: This is where the problems are, when the old harness goes out and the new one goes in there are only 4 or so harnesses that are being switched. when that is done there will not be enough power to the comp to make it power up and run the car you will need to tap into some power supplies, Ill post up later and tell you what color they are
Also, there will be some wires that you wont use hook up everything else that you know of. again this is one of those things that I will have to get back to you on I do know this off the top of my head:
1. use the alternator wires from your a3 (red and a little blue) place a small slide on terminal on the end of the old herness and stick it onto the BOTTOM pin of the alternator simply cut thesmall blue wire on the A3 HArness.
2. there is also a singl red/black wire next to the blue alternator wire on the new harness. put a spade termainal into the single harness and connect it to the starter, this is your starter turn on wire.
The downpipe
I have a 1992 GTI 8V I used the downpipe that came with my car and the exhaust mani fron the new engine no spacer was needed to make this work, maybe thats only an issue for CIS cars. Im not sure but Im just happy that I didnt have to buy one.
Ill update this as I remember if there are any questions email me or IM me and Ill include them into this post. HAVE FUN!!!

Here is the link to the pictures of the swap. Feel free to look at my other albums while your in there





Modified by X-FlowA2 at 4:07 PM 6-30-2003
 
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#1,005 ·
I feel dumb, and happy at the same time.
It is running, I had the plug wires in the right order, but not on the right plugs they were all one space too far clockwise. But she is running, I have my new c2 #42 software ordered, I think the lights are going to be a bit of a headache, I want to use the mkIII lighting harness. Then a bit of cleaning up, get the front end back on and she should be good to go.
One more quick question, when you use the ac delete pulley on the water pump, is it still ok to have the v-belt on as well? Or will it burn up? I want to keep the power steering, I think I may need a shorter V-belt between the power steering pump and the crank pulley.
 
#1,009 ·
Re:

So I am swapping a 94 ODB1 into my 91 GTI and have some questions:
I am using the following out of the 94:
Rear Beam
Gas Tank
Fuel Pump (no more external pump)
Engine and Headlight wiring harnesses
Radiator Fan shroud
K frame with PS
Not using AC
I am now down to wiring and have some questions:
1. Do I need to run a different harness to the in tank fuel pump
2. I have the following wires left over:
Single wire connector - Black with white stripe (pin 64 on computer)
Two wire connector - Grey with white stripe (pin 45 on CPU) and solid yellow (pin 21 on CPU)
Single Wire Connector - Black with Yellow strpie (pin 4 on a 4 pin harness in engine bay)
Two wire connector - Green w/ white stripe and solid green with solid yellow sliced together (green w/ white stripe goes to vacuum related thing near firewall in engine bay)
3. Can I use a 16v Pressure Plate with the 2.0 and an A3 trans?
also is there anything else i will need to do to make sure i will have no probs starting it? thanks in advance.
 
#1,011 ·
Re: Re: (abuthemagician)

he clearly stated he is gonna use a mk3 tank. he will use just the mk3 tank/pump/lines/filter.
you will need to wire up the new connector. it is pretty self explanitory.
the two wire connector is for the obd port. the black w/ yellow stripe needs constant power. the green wire connectors is for AC.
not sure on black with white stripe, i can check later.
you can use the 16v PP as long as you use matching flywheel. and big spline clutch disc
 
#1,012 ·
Re: (Satur9)

Okay, I'm lazy and short on time TODAY..... but unfortunately I'm also as impatient as I am curious.
I have a 89 CE2 Shell with a 16v harness in it
Goals are to have an ABA16vT in it
I want to use the Rado G60 Dash n Cluster I have, and would like it to be functional
What all do I need?
Someone, anyone, everone....
make me a list so I can just get this shizz started
There is a sore lack of respect for VeeDub in SC, and I'm bout to change that

Side note, everything that is supposed to sit infront of the motor is MISSING as in non-existant
Thanks in Advance
 
#1,014 ·
Re: Re: (bonesaw)

Thanks for the help. According to http://www.selenengineering.com/xECUPinouts.aspx the only black with white stripe goes to the Idle Air Control Valve. However that still doesn't really help me.
Quote, originally posted by bonesaw »
he clearly stated he is gonna use a mk3 tank. he will use just the mk3 tank/pump/lines/filter.
you will need to wire up the new connector. it is pretty self explanitory.
the two wire connector is for the obd port. the black w/ yellow stripe needs constant power. the green wire connectors is for AC.
not sure on black with white stripe, i can check later.
you can use the 16v PP as long as you use matching flywheel. and big spline clutch disc
 
#1,015 ·
Re: (bonesaw)

Quote, originally posted by bonesaw »
ask questions and people will answer. not what do i have to do. every single thing you wanted to know can be found on this forum.

I asked for a parts list, not step by step directions, you have PM reguarding your comment.
Can someone please list the parts since apparently it has changed several times since the Original Post
Has there been a cheaper and easier solution found to the whole pulley system? Bahn Brenner is a bit on the crazy side with their prices, and changing cranks causing the need to machine stuff is a bit beyond what I had in mind FOR NOW.
Thanks in advance for anyone willing to help


Modified by GermanRob at 8:11 AM 11-13-2007
 
#1,017 ·
Re: (_muppet_)

yeh, I'm reading that one too....
guess it would've made more sense to post in both eh?
Lemmie go fix that
quick edit for a quote from bonesaw:

if the car is ce2, get a mk3 instrument cluster harness. plug the cluster in. everything should work. depending on what you did with the engine harness there should be a plug for the VSS that will have to be reinstalled. gas gauge may not be as accurate. I beleive you can mail it out to reset the mileage.
One down several to go.... thanks dude



Modified by GermanRob at 10:57 AM 11-13-2007
 
#1,018 ·
Re: THE OFFICIAL X-FLOW SWAP POST!!!!!! (X-FlowA2)

Im sure its in here some place BUT do I need the Gauges for an OBD2 swap? I want to swap this into a 91 Passat.
 
#1,019 ·
Re: (GermanRob)

Quote, originally posted by GermanRob »

quick edit for a quote from bonesaw:

if the car is ce2, get a mk3 instrument cluster harness. plug the cluster in. everything should work. depending on what you did with the engine harness there should be a plug for the VSS that will have to be reinstalled. gas gauge may not be as accurate. I beleive you can mail it out to reset the mileage.
One down several to go.... thanks dude


Modified by GermanRob at 10:57 AM 11-13-2007

i dont get it?
 
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