My 91 GTI 8 valve to B4 1Z TDI swap

[G60ING]

How was vibration inside the car affected by the new mounts?

So far NVH has been no worse with the stiffer mounts.

thanks, I was wondering about the vibration with these. I think I'll be doing these some day soon.

 

[GTiTDi]

thanks, I was wondering about the vibration with these. I think I'll be doing these some day soon.

I will report back once I do some more driving

So far the car seems to be great with these bushings, no added vibration but a lot less movement...

The only vibration I sense now is when cold at idle, and it seems to be from my exhaust, which is rather rigidly mounted at the rear of the car...I may even include a second flex section when a make a new exhaust system.

To clarify what I was saying when I said I reinforced my front engine mount, I filled the voids with a hot glue gun, which eliminates a lot of the sag and overall sloppiness of the stock rubber mount.

 

[GTiTDi]

The GTI seems to be well sorted, and I haven't been messing with it much. Another project has started up, something to keep the creative juices flowing, something along a less beaten path....
http://forums.tdiclub.com/showthread.php?t=365168

 

[GTiTDi]

Wow this month marks two years on TDI club...so much has happened (and been learned!) in a short amount of time!

 

[TDI-JAY]

awesome build. just read 17 pages, eyes burn.

 

[sootie]

Wow great swap, excellent workmanship and way to stick with it.

 

[Jake_S]

I just read the whole thread. Great work and definitely an inspiration for performing a similar swap.

Jake

 

[GTiTDi]

awesome build. just read 17 pages, eyes burn.

That's a lot to read in one sitting! If you make it to one of the gtg's you might even get to go for a ride!

Wow great swap, excellent workmanship and way to stick with it.

Thanks!

I just read the whole thread. Great work and definitely an inspiration for performing a similar swap.
Jake

Thanks Jake. Making this build thread was meant to assist as well as inspire others to do this swap!

 

[GTiTDi]

Dream come true...will be working at Smyth Performance very soon!
January of this year I drew this up on MS paint because I thought nothing could be better than a Jetta TDI turned into a truck....

Now nearly a year later I will be not only building a Jetta TDI truck, but getting paid to do so!

I will be doing swap work and selling turbo adapter plates too...chk out my FB page http://www.facebook.com/pages/Schnell-Snail-TDI-performance/188243454529795

 

[jstn]

congrats broski! ive heard smyth is kind of into this tdi thing...

justin

 

[clyde]

"…nothing…better than a Jetta TDI turned into a truck…"

Is your sketch based on a Mk3 Jetta?

 

[GTiTDi]

Is your sketch based on a Mk3 Jetta?

Yes. The ones we are going to be making are mk4 based, mainly because of their prevalence, nice interior amenities, and rust resistance...

 

[G60ING]

Congrats

 

[IndigoBlueWagon]

Jetta wagon made into a truck would be excellent, but the B pillar is too far forward for anyone but a pretty short person (me, perhaps) to drive comfortably. A 2-door Golf would be better, but that would make for a really short truck bed.

 

[GTiTDi]

Jetta wagon made into a truck would be excellent, but the B pillar is too far forward for anyone but a pretty short person (me, perhaps) to drive comfortably. A 2-door Golf would be better, but that would make for a really short truck bed.

Don't worry about that, we are keeping the taller people in mind! There will be a quarter window.....

 

[GTiTDi]

145hp/257ft/lbs and no heavy smoke output**....egts barely exceed 1300*....130 mph...superb mileage! No MAF or N75 to worry about failing....100% Win


**tested using B100 from Loud Fuel, Falmouth, MA

 

[GTiTDi]

Next step with the GTI TDI is an 11mm fuel pump from an ALH....this has been on the back burner now that I have been moving into my own shop for performing more swaps, diagnostic services, as well as timing belts and clutch jobs. As well as this operation I will be working at Smyth Performance along with Mike aka ManualTranny! Looking forward to some good times!

 

[baja_brewer]

Wow, not sure how I missed all the good news posted on the last page. Congrats!

I have all the parts needed for my 11mm pump swap, but I don't have the ability to do the minor machining I've read is required - think I could send this your way when the time comes? Maybe bring the parts when I come up to buy that adapter plate?!

I'm trying to get everything together so I can get this done by spring.

 

[GTiTDi]

Wow, not sure how I missed all the good news posted on the last page. Congrats!

I have all the parts needed for my 11mm pump swap, but I don't have the ability to do the minor machining I've read is required - think I could send this your way when the time comes? Maybe bring the parts when I come up to buy that adapter plate?!

I'm trying to get everything together so I can get this done by spring.

I have just the machinist to bring your bracket to. He has already done a couple and will be doing mine as well. Come visit before the GTDI gets stowed away for the winter!!

 

[AndyBees]

Awesome! For radical, what else can one say?

 

[GTiTDi]

Awesome! For radical, what else can one say?

Thanks Andy!

 

[mike000]

The 1Z is a tight fit at least on the belt side

Sorry to go so far back, but I used an ABA PS pulley on the crank, along with the stock TDI serp pulley, as I had some clearance issues with the stock PS pulley. I don't recall if you kept your power steering or not, but it made things super easy for me! The ABA pulley is smaller, because it has a higher RPM range (at least my theory), so to keep the pump spinning at the same speed as an equivalent gasoline motor would, the TDI needed the bigger pulley for the gear ratio, but in all reality, it doesn't make a damn difference lol, mine drives just fine with the different pulley combination!

 

[Abacus]

Curious about your 2000 Saab 9-5 intercooler. Is it holding up to your boost pressure? Which model/engine (8th VIN digit) did it have?

 

[GTiTDi]

Curious about your 2000 Saab 9-5 intercooler. Is it holding up to your boost pressure? Which model/engine (8th VIN digit) did it have?

As far as the "8th VIN digit" I have no idea, but FWIW Burpod had no issue finding one for cheap off ebay...IIRC it was a 2.0 turbo.
It seems to be holding up fine considering I am running 28 psi of boost through it.
The real question is would it even fit a B4.....I will let you know once I commence swapping my mk3 tdi drivetrain into my B4V GLX....

Edit: the Saab intercooler has failed. I noticed smoke output and a slight air hiss under boost, investigated for leaks and found the intercooler is leaking. The lowest tube and one of the upper ones have expanded, kind of like they were inflated like a balloon.

[/url] image by dr.vdub, on Flickr[/IMG]

[/url] Intercooler upgrade by dr.vdub, on Flickr[/IMG]
I have been fitting a more robust spearco intercooler that I got from my buddy yeah dude 38

[/url] Intercooler upgrade by dr.vdub, on Flickr[/IMG]

[/url] Intercooler upgrade by dr.vdub, on Flickr[/IMG]

 

[Urbandiesel]

Gti tdi

I was reading thread here and was wondering how much will it run me to have someone from this forum build me a mk2 tdi providing I supply the car or rolling shell I'm not good with tools what so ever Thanks

 

[GTiTDi]

I was reading thread here and was wondering how much will it run me to have someone from this forum build me a mk2 tdi providing I supply the car or rolling shell I'm not good with tools what so ever Thanks

Sending you a PM

 

[GTiTDi]

[/url] Intercooler upgrade by dr.vdub, on Flickr[/IMG]
finally, making my own boost pipes...TIG welding is fun!

[/url] Intercooler upgrade by dr.vdub, on Flickr[/IMG]
My new improved boost pipe...note the smoother path...old setup sitting above for comparison

[/url] Intercooler upgrade by dr.vdub, on Flickr[/IMG]
trying to determine best spot for my mk4 3-bar map sensor...I think I will go with spot #2

[/url] Intercooler upgrade by dr.vdub, on Flickr[/IMG]

 

[MR-FIZZLE-89]

What size intercooler piping ya going with there?

Wicked build thread btw

 

[GTiTDi]

What size intercooler piping ya going with there?

Wicked build thread btw

Thanks! It has been a good time.

IIRC, the majority of the plumbing is 2" which steps up to 2.5" at the intercooler and then back down to 2"

 

[MR-FIZZLE-89]

Ive been watching this thread for a while as im collecting parts for a similar build myself all be it with a slightly different variation of the GT2052 which comes from a Landrover TD5 engine. You did reply to one of my posts asking if it would be a suitable turbo.

I asked about the I/C tubing as I have some 2.25" tubing doing nothing and was going to use it for my I/C plumbing...

Do you think this diamter all the way through would be ok?