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    Thread: My 91 GTI 8 valve to B4 1Z TDI swap

    1. Member killacam1111's Avatar
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      91 GLI, 00 Jetta GLX, 00 Jetta TDI, 04 passat 1.8T wagon, 99 2.0 beetle
      03-13-2011 10:15 PM #51
      build is coming along nicely! cant wait to see this thing on the road!
      CapeCod GTG | Grim Water
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      Quote Originally Posted by vwjettalikewhoa View Post
      haha this is redic I should have reported this to a moderator. <p>wait i did..

    2. Member FaithInMkIII2.0's Avatar
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      03-16-2011 05:33 PM #52
      should have more pictures up soon once I get my other computer clear of viruses..
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    3. Member FaithInMkIII2.0's Avatar
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      '91 GTI TDI powered, '99 T4(soon to be TDI), '79 Audi Fox
      03-17-2011 08:45 PM #53
      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]
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    4. Member FaithInMkIII2.0's Avatar
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      03-17-2011 09:00 PM #54
      [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]
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
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    5. Member
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      2010 Golf TDI 6M 2Dr
      03-17-2011 09:53 PM #55
      Quote Originally Posted by 89GLI16V View Post
      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?

      Quote Originally Posted by FaithInMkIII2.0 View Post
      sweet see you there! If you ever visit the Cape let me know!
      What part of the Cape?

    6. Member FaithInMkIII2.0's Avatar
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      03-17-2011 10:29 PM #56
      Right near da beach..

      Falmouth
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    7. Member FaithInMkIII2.0's Avatar
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      03-17-2011 10:31 PM #57
      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.
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    8. Member FaithInMkIII2.0's Avatar
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      03-21-2011 10:35 AM #58
      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!!!
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    9. Member FaithInMkIII2.0's Avatar
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      03-22-2011 05:25 PM #59
      Last edited by FaithInMkIII2.0; 06-14-2013 at 12:41 AM.
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    10. n00b
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      85 8V GTi, MKIV Jetta 2.Slow 270k when sold.
      04-06-2011 01:01 PM #60
      Great build! How about a pic of the finished smic?

    11. Member FaithInMkIII2.0's Avatar
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      '91 GTI TDI powered, '99 T4(soon to be TDI), '79 Audi Fox
      04-09-2011 01:14 PM #61
      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]
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    12. Member FaithInMkIII2.0's Avatar
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      04-09-2011 01:40 PM #62
      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]
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    13. Member FaithInMkIII2.0's Avatar
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      05-12-2011 12:09 PM #63
      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!
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    14. Member FaithInMkIII2.0's Avatar
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      05-16-2011 12:32 PM #64
      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]
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    15. Member FaithInMkIII2.0's Avatar
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      06-04-2011 10:01 PM #65
      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]
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    16. Member Volkswageneer1990's Avatar
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      06-16-2011 03:33 AM #66
      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
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    17. Member FaithInMkIII2.0's Avatar
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      07-19-2011 05:20 PM #67
      Quote Originally Posted by Volkswageneer1990 View Post
      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!
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    18. Member FaithInMkIII2.0's Avatar
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      '91 GTI TDI powered, '99 T4(soon to be TDI), '79 Audi Fox
      07-19-2011 05:31 PM #68
      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
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    19. Banned zukiphile's Avatar
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      07-20-2011 12:13 PM #69
      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.

    20. Member FaithInMkIII2.0's Avatar
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      07-20-2011 05:30 PM #70
      Quote Originally Posted by zukiphile View Post
      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.
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    21. Member FaithInMkIII2.0's Avatar
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      07-24-2011 06:13 PM #71
      European Car magazine readers may recognize the red Audi 90 Quattro coupe parked next to my Gti from this month's issue...nicknamed "The Crow"..even with a melted #5 piston, it is still an awe inspiring machine, with a bark so loud from its 4" side exit its beyond comparison
      [IMG][/IMG]
      [IMG][/IMG]
      [IMG][/IMG]
      [IMG][/IMG]
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    22. Member FaithInMkIII2.0's Avatar
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      07-24-2011 06:15 PM #72
      [IMG][/IMG]
      a tshirt KillaCam devised based on a nickname from JohnBarleyCorn
      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

    23. Member killacam1111's Avatar
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      07-24-2011 11:51 PM #73
      Quote Originally Posted by FaithInMkIII2.0 View Post
      [IMG][/IMG]
      a tshirt KillaCam devised based on a nickname from JohnBarleyCorn
      where's the like button?
      CapeCod GTG | Grim Water
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      Quote Originally Posted by vwjettalikewhoa View Post
      haha this is redic I should have reported this to a moderator. <p>wait i did..

    24. Member FaithInMkIII2.0's Avatar
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      09-06-2011 06:30 PM #74
      well I melted a piston as well...a few miles of triple digit speeds brought my EGTs up a bit too high..and I am not sure yet but I may have a failing injector. Honed the cylinders already, the block is gonna be ok, hopefully getting a used piston from a local guru, as well as getting my injectors checked out. Going to balance the pistons and rods while I have them out, as well as clean up the intake ports of the head.



      For VW TDI modification, parts, and service check out SCHNELL SNAIL TDI PERFORMANCE yes, we do gassers too!
      Southbend clutch dealer TIG welding

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      09-07-2011 12:12 AM #75
      OUCH!

      ive done the same.. heat seized my 1.6 going up a hill at a little over 100 mph. except i just re-started the engine after it cooled down, and have been driving it since. no rebuild for me

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