My 91 GTI 8 valve to B4 1Z TDI swap

[FaithInMkIII2.0]

Wow! That GTI was in good shape. Are you keeping the ECU or going to an M-TDI injection pump.

When it's complete, you'll need to make a trip to Ho5G and let Rocketchip work his magic on it.

Keep an eye on this section of TDIClub for a GTG. They usually have one in May or June. http://forums.tdiclub.com/forumdisplay.php?f=33

I am keeping it electronic, never planned on making it an MTDI, and I am planning on ecu upgrades..I would definitely like to make it to the gtg, I have never been to Portland, but I don't know if I will be able to take off the necessary time to make the trip.

[madduc79]

[OttoSchultz]

I am keeping it electronic, never planned on making it an MTDI, and I am planning on ecu upgrades..I would definitely like to make it to the gtg, I have never been to Portland, but I don't know if I will be able to take off the necessary time to make the trip.

Portland? Ho5G is in southern NH, just north of Haverhill.

[89GLI16V]

Great build. You'll love this car. I built a TDI powered '88 Coupe and it was such a good car.


I reswapped the car to an ABA before I sold it last year. I have a small pile of A2 TDI parts you may be interested in. There's a side exit exhaust that sounded so sweet, a converted airbox, a one off IC pipe and a full A3 IC system. There may be some other parts too, but that's all I can think of right now. Let me know if you're interested.

[FaithInMkIII2.0]

Portland? Ho5G is in southern NH, just north of Haverhill.

sweet see you there! If you ever visit the Cape let me know!

[FaithInMkIII2.0]

Great build. You'll love this car. I built a TDI powered '88 Coupe and it was such a good car.


I reswapped the car to an ABA before I sold it last year. I have a small pile of A2 TDI parts you may be interested in. There's a side exit exhaust that sounded so sweet, a converted airbox, a one off IC pipe and a full A3 IC system. There may be some other parts too, but that's all I can think of right now. Let me know if you're interested.

I am interested..I was going to try one S4 biturbo intercooler but I still don't know if its even up for grabs, a customer had me install some big intercoolers and carbon ducts on to his S4 wagon, but left the stock parts at the shop! shoot me a PM with pics or whatever, and maybe where in the sticks you are, Im on Cape

[FaithInMkIII2.0]

started the gti tonight..had a hell of a time reading through the four different wiring diagrams, testing, checking continuity, enough to make my head spin! not having all the grounds hooked up sent me for a loop, but figured it all out and
started it right up!

[FaithInMkIII2.0]

Picked up a bunch of useful goodies last Sunday..including a side exit...
[IMG][/IMG]

restored the finish on my 200k plus yet mint bilsteins and neuspeed sofsports...[IMG][/IMG]

[scottyrocco16vDUB]

200k plus susp???? now that is impressive!!! nice build!

[punkvideo81]

nice build!

[slavik19]

you only paid $500 for tht BEAUTIFUL thing!

[FaithInMkIII2.0]

So I now have an airbox, I used a Digifant box with B4 tdi MAF sensor mounting boss glued to it. Thanks again to 89GLI16V for the idea and the already slightly modded digi box...I took your idea and went with it...[IMG][/IMG]

[IMG][/IMG]
[IMG][/IMG]
[IMG][/IMG]
[IMG][/IMG]

[FaithInMkIII2.0]

also I have gotten the Mk3 intercooler in as well as modified an audi s4 intercooler duct to fit the GTI! more pictures in a little bit!

[FaithInMkIII2.0]

a comparison between the modified digifant box and the stock untouched (except removed airflow meter) digifant box
[IMG][/IMG]

[89GLI16V]

Things are looking great! I'm pleased that those parts will be put to good use again. Enjoy it Chris.

[killacam1111]

build is coming along nicely! cant wait to see this thing on the road!

[FaithInMkIII2.0]

should have more pictures up soon once I get my other computer clear of viruses..

[FaithInMkIII2.0]

Here is the slightly modified S4 intercooler duct, which I notched and cut to fit around the fender, also I have since cut out the hole meant for the brake cooling duct...[IMG][/IMG]
This is the hole I had to make in the fender to clear the SMIC.
[IMG][/IMG]
[IMG][/IMG]
And the hole in the inner fender..
[IMG][/IMG]

[FaithInMkIII2.0]

[IMG][/IMG]

EGT gauge from an airplane, thanks Dad! (He is a multi-engine rated commercial pilot and an AP/IA aircraft mechanic) TDI grill and tail badges from Jake aka 89GLI16V
[IMG][/IMG]

[OttoSchultz]

Great build. You'll love this car. I built a TDI powered '88 Coupe and it was such a good car.


I reswapped the car to an ABA before I sold it last year. I have a small pile of A2 TDI parts you may be interested in. There's a side exit exhaust that sounded so sweet, a converted airbox, a one off IC pipe and a full A3 IC system. There may be some other parts too, but that's all I can think of right now. Let me know if you're interested.

You swapped it back?!?

How far into the sticks are you?

sweet see you there! If you ever visit the Cape let me know!

What part of the Cape?

[FaithInMkIII2.0]

Right near da beach..

Falmouth

[FaithInMkIII2.0]

that Coupe with the TDI was swapped to a 2.0 and sold, I bought some of the parts that were used with the tdi and left over.

[FaithInMkIII2.0]

My GTI moved under its own power this morning, still have some things to square away before a real test drive but its nice to start it up and drive it! Can't wait to upload a video of it running, an audio track would be good enough, the side exit sounds mean!!!

[FaithInMkIII2.0]

[dragon68]

Great build! How about a pic of the finished smic?

[FaithInMkIII2.0]

A3 TDI SMIC
[IMG][/IMG]
modified S4 SMIC duct
[IMG][/IMG]
Fender resprayed with martin seynour SS urethane L90E alpine white! all holes have been finished with a deburring tool, nice and smooth
[IMG][/IMG]
Planning on grafting a IC vent into the stock fender liner
[IMG][/IMG]

[FaithInMkIII2.0]

Mounted the B4 reservoir in the notch of the washer reservoir, seemed like a natural location!
[IMG][/IMG]
from the reservoir I used an A2 feed hose which connects to the B4 feed pipe which I fitted into the channel of the underside of the A2 radiator support. I used the B4 pressure pipe, fit no problem. Also in this pic is the corrado lower radiator hose, which gave me room for the AC compressor. [IMG][/IMG]
[IMG][/IMG]
Here you can see the A3 feed hose disappearing above the motor mount support where it attaches to the B4 feed pipe.
[IMG][/IMG]

[FaithInMkIII2.0]

I have been driving my swap and so far am very pleased with the results!

However, there are some bugs to work out. Mainly I have an intermittent power loss situation that doesn't trigger an MIL. After restarting it seems like the power is restored. I have posted in TDIclub as well. Also I see air bubbles constantly in the fuel line to the IP. Thinking this may be more than one issue. Any help is most appreciated!

[FaithInMkIII2.0]

The air in the fuel was due to a bad thermo-T, apparently a fairly common problem with B4s and A3s. The flashing glow light was due to a misadjusted brake pedal switch. Now I have Cruise control.

here it is at Dubs in the Sand
[IMG][/IMG]

[IMG][/IMG]

[FaithInMkIII2.0]

The TDI has been great to say the least!!! Plenty of torque and acceleration for stock tune, but a set of Bosio Sprint nozzles are going in, as well as a Rocketchip tune at HO5G hopefully! Took it on a trip to Wolfeboro NH and back with out any issues, 45 mpg and not even trying! I am starting to like this one much more than my Jetta Coupe ABA!! Much quieter on the highway and it has a straight side exit!? [IMG][/IMG]
[IMG][/IMG]

[Volkswageneer1990]

Hey Kudos to you man. The car and the build were excellent. I am thinking of doing that so I can get double my gas milage and get it up to 45. Not much gas money floating around at 15...

Fun and Practicality in a car. Congrats

[FaithInMkIII2.0]

Hey Kudos to you man. The car and the build were excellent. I am thinking of doing that so I can get double my gas milage and get it up to 45. Not much gas money floating around at 15...

Fun and Practicality in a car. Congrats

Thanks dude! It has been a fun build so far, even more so now that I have it Rocket chipped with 20lbs of boost! My fuel mileage is even better! I can literally hammer this thing all day and it barely uses any fuel, for instance I drove it 4.5 hrs to Waterfest last weekend, around a 300 mile trip and used a quarter of a tank! That was with plenty of draggin and 110 mph pulls!

[FaithInMkIII2.0]

So I haven't updated the thread in a while mainly because it is summer and I have been wicked busy!

HO5G was awesome. A TDI specific gtg in NH that is an annual event, I was glad to go and meet some interesting people. What made it an awesome time however was getting the TDI tuned by Jeff of Rocketchip, who took the time to make me two sets of chips in a row since the data logs from the first set were less than ideal. Now pushing 20lbs of boost, it rips to say the least! Before HO5G I installed a set of Bozio Sprint nozzles to help deliver some more fuel! Most recently I installed a PD lift pump into a spare A3 ABA fuel sending unit that I had kicking around. It helps dramatically with low speed operation as well as helping with higher RPM fuel delivery.

Took it to Waterfest this past weekend, had a great time showing it off, but partied too hard and ended up arriving too late to the show on sunday so I didn't enter it

Met a lot of new people from all over the place, that was the best part to me. Well except for my friend Janis revving his 800 hp 90 S2 Quattro at 4am in the hotel parking lot...Launch control and a 4inch side exit makes for a lot of noise....5 cruisers worth lol

[zukiphile]

I know that I lack the knowledge, skill, determination and focus to do what you've shown in this thread. That makes me admire it all the more.

[FaithInMkIII2.0]

I know that I lack the knowledge, skill, determination and focus to do what you've shown in this thread. That makes me admire it all the more.