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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old July 27th, 2015, 22:44   #16
IndiaRed
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Default The engine moves in

Finally this weekend I was able to get the engine/transmission installed in the car. It went in fairly easily. There is not much extra room though. I had to remove the fuel filter to give me a bit more wiggle room to get the engine mounts to align. The filter is back in.

The waiting engine bay.



The engine and transmission were mostly assembled on the dolly. I installed the wiring harness and (especially the stuff that sits atop the transmission).



The engine being lowered and rolled into place. I had a small jack under the rear of the transmission to help adjust the approach angle. I also used all four lift points to help balance the transmission better (and to spread the load). I ended up fabricating a couple of lift brackets.



And lastly the engine in place.


Last edited by IndiaRed; July 27th, 2015 at 22:46.
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Old July 30th, 2015, 04:38   #17
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That is a clean engine compartment.
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Old August 3rd, 2015, 15:13   #18
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And very busy looking.
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Old August 6th, 2015, 21:17   #19
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Default Nearing the finish

Most of the car is together now. Really just the bumper, coolant reservoir and some plastic covers to install. Oh, and getting the ECM to talk to the cluster....

Engine bay almost complete:



Front radiator and intercoolers. The 1.8T steering cooler bar is the wrong shape and is currently just tied into place while I wait for the AFB version.



Some close ups of the intercooler with their air guides in place.



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Old August 6th, 2015, 21:25   #20
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Default Underbody views

The front end under the engine is quite busy with the AC pipes, suspension, intercooler hoses and exhaust. Not much extra room here, but it all fit and went together fairly smoothly.







A few shots of the exhaust. This is the used stock exhaust system (very heavy). I had to cut open the catalytic converters to clean them. They were 50%+ blocked. I used new pipe connectors and few new rubber hangers. Everything fit perfectly.



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Old August 10th, 2015, 17:44   #21
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Very nice!!! Ive been contemplating a 2.5 swap, just not sure if I want to run something with little support stateside if I need parts or something. But I know how good those things sound... and the low end torque...!!!
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Old August 16th, 2015, 15:55   #22
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Very Nice!
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Old August 20th, 2015, 08:41   #23
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k-harley - The trickiest part is getting the engine (block & heads). Most everything else is available new from a few European sources and used on eBay.de or eBay.co.uk. I suspect most US based TDI shops should be able to figure out this engine. However, with all the new parts it is not cheap. My goal is to make this reliable for the next 10 years / 100k+ miles.

Started the engine up last week after finally getting the air bled out of the fuel lines. Runs like crap. Did the dynamic tuning check in VAG-Com and advanced the timing at bit on the belt sprocket for the injection pump. Won't rev above about 1,800 rpm and smokes big time. VAG-Com shows the 00550 - Start of Injection Regulation 17-10 Control difference - intermittent. Checked most of the other things that could cause this and have now purchased a rebuilt injection pump from Diesel Bob in the UK. Also, since I am this deep I have new intercoolers and a MAF coming as well.

So, while I am waiting for this I am wrapping up the wiring modifications. There is one wire that shows up on the AFB wiring diagram but is not in any of the wiring harnesses I have. It is wired on the chassis side of the plenum connector to the Airbag control unit. The gasser AWM had this in the engine harness. It is easy to add, BUT, I have no idea how to reference the diagram ECU pin numbers with the pin numbers on the three ECU connectors. The three connectors have pin numbers 1-24, 1-40, and 1-52. So, for example, the ECU has three pin #19's. I have been able to identify where all the wires in the harness connect in the ECU plugs, but there is no pattern that make sense for referencing between the ECU pins identified in the diagram with the physical pins in the three connectors.

So, where is pin 47 (Air Bag Control Unit J234) on the ECU?
Thanks to anyone who may know.

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Old September 11th, 2015, 13:26   #24
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Update - Received the rebuilt injection pump from Diesel Bob in the UK. Two hours later the beast was installed. Engine runs much better and actually revs up like it should. DTC codes have gone. Still smokes too much. Waiting on some new intercoolers (one looks like it is leaking oil, so may also not be holding turbo pressure), and new MAF sensor. I drove it around the block for the first time - saw a few dirty looks from folks left in the smoke wake. It smokes less with the MAF disconnected (running with MAF default setting).
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Old November 9th, 2015, 14:36   #25
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Update - I have about 200 miles on the setup. Running much better now. Still smells a bit too much of diesel in the exhaust. The engine also seems a bit loader than I expected. I currently have the ECU out for tuning to match up with the larger injector nozzles. Recent work/adjustments completed.

Replaced the intercoolers with new units.



The engine was making a hollow knocking sound that I traced to the hydraulic lifters. You could hear this with the air filter disconnected and feel it on one of the fuel lines to the injectors. Pulled the cams and replaced all the lifters and rockers. I should have done this with the engine rebuild. Noise is now gone and I have less smoke.






Turbo - I belatedly noticed that the top of the actuator housing was bashed in. This inhibited the range of motion of the actuator rod by 1/4". I replaced with a new unit and calibrated to start opening around 3-4 inHg and be fully open at 18 inHg.

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Old November 13th, 2015, 18:20   #26
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I got my ECU back from the tuner. "Jetta ,97" on the forum did the tuning - very fast turnaround and fair price. Car runs great now. More power to go along with the larger injector nozzles. Now its time to put some miles on and fix the last few non-TDI items (radio/speakers, etc)...

http://forums.tdiclub.com/showthread...ighlight=marin

Last edited by IndiaRed; November 13th, 2015 at 23:23.
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Old April 30th, 2016, 22:51   #27
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Default 5,000 mile update

I have not posted in awhile. So far I have managed 5k fairly trouble free miles. Recently the old fan blade broke apart damaging the radiator and hood insulation. I just finished replacing these items.

The car is a bit stinky when running so I wanted to try and clean up the exhaust a bit. To that end I added the pre catalytic converter that was available on the engines after the AFB (I believe the b6 models had them). This was a matter of cutting off the pipe below the flex joint and fitting a new flex joint and mounting flange for the pre-cat. I had to make a custom flange to mate to the pre-cat flange out of stainless. The hole in the pre-cat is an inspection hole (welded in an 02 bung). That way I can check to see if the element is clogging up.







and finally the pre-cat in place as viewed from the top.



I did need to bend the vacuum pump heat shield a bit to clear the side of the cat.
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Old April 30th, 2016, 23:05   #28
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Default Further exhaust cleanup

To improve the exhaust further I removed the center muffler (which weighs some 25 lbs) and replaced it with an aftermarket DPF. This filter does not require the computer generated regeneration, but does it passively when hot enough and run long enough at higher rpms - periodically. It is from HJS, a German company.

http://www.hjs-motorsport.de/product...r-filters.html

This involved cutting out the center muffler and inserting the DPF along with some new pipe and a support bracket. Note, I also added two small pipes that connect to the Audi pressure differential sensor that normally monitors how "plugged up" the filter is. I want to be able to monitor it to verify that it is actually working. The sound of the car running is no different after this swap (my biggest concern initially other than cost).

A side by side comparison of the old and new setup.





I still need to test using the clean white rag held at the tailpipe. Before it would definitely start showing the black soot (along with the soot layer on the back of the rear hatch).
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Old May 1st, 2016, 06:17   #29
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Awesome. Thanks for the update. I like that you're building/modifying the car to suite your needs which in this case includes cleaning the exhaust up. You might be the first guy on this club to do such a thing. As you can guess it's much more typical to yank off all of these after treatment devices. Kudos on the top notch work.
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Old February 5th, 2019, 23:10   #30
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Update. The car just turned 30k miles on the conversion. The exhaust on this car has always been a bit stinky. Last week I was driving when I heard a loud pop. The car then ran really rough with a loud acoustic thumping sound. You could really hear it from the intake area with the hood/bonnet up. Based on some research it seemed likely to be a rocker that came off or a bad cam lobe. So.... I pulled both valve covers and found that one intake rocker on the 1-3 bank was off and two intake rockers on the 4-6 side and one exhaust rocker on the 4-6 side. Some of the cam lobes show significant wear.

I can't believe that all four would have popped off at the same time. So perhaps my smelly exhaust, and not quite the power I was expecting, suggests that some of the rockers may have been off for a long time? Any thoughts?

I am a bit concerned about possibly having bent a valve in the moment when the rocker is coming off. When I turn the crank by hand I hear air escaping from the 4-6 bank.
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