1991 B3 Passat Wagon AHU Syncro Swap

oil_me

Veteran Member
Joined
Oct 8, 2004
Location
Woodstock, NY
TDI
Black '99 Jetta, Glacier Blue Audi 80 Quattro TDI
Thanks for detailing the process so well. May you be well rewarded for all your extraordinary effort.
 

AKAvant

Veteran Member
Joined
Oct 12, 2010
Location
Europe
TDI
2004 Audi A4 Avant 1.9TDI Quattro, 2002 VW California, 1998 Jetta TDI (Sold 6/16), 1997 B4 Passat TDI, 1993 Eurovan Weekender 1Z m-TDI conversion (Sold 5/12), 1992 AHU powered B3 Syncro Wagon
Progress. The gt body kit takes awhile to install properly.


 

AKAvant

Veteran Member
Joined
Oct 12, 2010
Location
Europe
TDI
2004 Audi A4 Avant 1.9TDI Quattro, 2002 VW California, 1998 Jetta TDI (Sold 6/16), 1997 B4 Passat TDI, 1993 Eurovan Weekender 1Z m-TDI conversion (Sold 5/12), 1992 AHU powered B3 Syncro Wagon
Sorry for the lack in updates. Moving into a new house/shop and helping parents also move into a new place has taken up most of my spare time over the last few months.
But the Passat is almost done. Just passed 335miles since the build. Motor is still in the break-in phase so no long drives at the moment, just alot of city driving.
Anyone have a recommendation on at what mileage I should change the initial oil? 500miles? And any recommendation on how long I should vary speed before a roadtrip with extended periods of the same speed is ok? 1000miles?
But she drives amazing. The syncro is pretty impressive in the snow. I'm still chasing down the usual little issues after a build like this. I'm only running a cat with no muffler at the moment and its a tad loud so I'll probably install a muffler.
I'll have a full photoshoot hopefully here in the next few weeks to better showcase the car, engine bay, interior etc.





Full tint and the front end 50% Clear Bra'd.



Summer Wheels. Before an alignment and before the exhaust was installed.



Potential new winter wheels. E30 325ix 15"x7" ET41 BBS RZ's.
 

AKAvant

Veteran Member
Joined
Oct 12, 2010
Location
Europe
TDI
2004 Audi A4 Avant 1.9TDI Quattro, 2002 VW California, 1998 Jetta TDI (Sold 6/16), 1997 B4 Passat TDI, 1993 Eurovan Weekender 1Z m-TDI conversion (Sold 5/12), 1992 AHU powered B3 Syncro Wagon
I've been researching the edl aspect of the abs with respect to the syncro drivetrain. I'm hoping the freewheel prevents any front rear lockup.
 

AKAvant

Veteran Member
Joined
Oct 12, 2010
Location
Europe
TDI
2004 Audi A4 Avant 1.9TDI Quattro, 2002 VW California, 1998 Jetta TDI (Sold 6/16), 1997 B4 Passat TDI, 1993 Eurovan Weekender 1Z m-TDI conversion (Sold 5/12), 1992 AHU powered B3 Syncro Wagon
Adjusted IQ values to 4.4-4.6 tonight, smoothed out the idle extremely. Still a tad of vibration, regretting the solid tranny mount. Might swap for a hydraulic.
 

AKAvant

Veteran Member
Joined
Oct 12, 2010
Location
Europe
TDI
2004 Audi A4 Avant 1.9TDI Quattro, 2002 VW California, 1998 Jetta TDI (Sold 6/16), 1997 B4 Passat TDI, 1993 Eurovan Weekender 1Z m-TDI conversion (Sold 5/12), 1992 AHU powered B3 Syncro Wagon
Looking forward to summer
 

G60ING

Top Post Dawg
Joined
Aug 5, 2001
Location
MD
TDI
No TDIs Currently, I have an R36 Corrado. I've had an ALH Corrado swap, AHU Corrado swap and 2003 TDI Jetta
You already know I love your car, that garage is the HUGE!:) I really like it
 

vanbcguy

Veteran Member
Joined
Feb 22, 2013
Location
Vancouver, BC
TDI
'93 Passat - AHU mTDI with GTB1756VK
Awesome looking car. If I could find a B3 wagon body that nice I'd be dropping my AHU in there so fast....

Sent from my HTC One XL using Tapatalk
 

AKAvant

Veteran Member
Joined
Oct 12, 2010
Location
Europe
TDI
2004 Audi A4 Avant 1.9TDI Quattro, 2002 VW California, 1998 Jetta TDI (Sold 6/16), 1997 B4 Passat TDI, 1993 Eurovan Weekender 1Z m-TDI conversion (Sold 5/12), 1992 AHU powered B3 Syncro Wagon
I was lucky to find the B3, was the motivation for the project. Everything else fell into place. The old huge shop is sold and gone. This is my new place. The 1Z from the B4 will be going into the '82 diesel Westy. Next project:)
 

G60ING

Top Post Dawg
Joined
Aug 5, 2001
Location
MD
TDI
No TDIs Currently, I have an R36 Corrado. I've had an ALH Corrado swap, AHU Corrado swap and 2003 TDI Jetta
I'm still in love with your garage space :)
 

AKAvant

Veteran Member
Joined
Oct 12, 2010
Location
Europe
TDI
2004 Audi A4 Avant 1.9TDI Quattro, 2002 VW California, 1998 Jetta TDI (Sold 6/16), 1997 B4 Passat TDI, 1993 Eurovan Weekender 1Z m-TDI conversion (Sold 5/12), 1992 AHU powered B3 Syncro Wagon
New shoes and winter stance. Anybody want some pepperpots?
 
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G60ING

Top Post Dawg
Joined
Aug 5, 2001
Location
MD
TDI
No TDIs Currently, I have an R36 Corrado. I've had an ALH Corrado swap, AHU Corrado swap and 2003 TDI Jetta
Keep the pepperpots until you have run the bbs long enough to have cleaned them once or twice while it's somewhat cool out, which is probably a warm day for you. Your fingers will freeze
 

bbob203

Veteran Member
Joined
Oct 31, 2012
Location
Louisville, ky
TDI
b5.5v
If that f150 wasn't lurking in the back round this would be like a shot into 1997 when that car was only 5-6 years old.
 

AKAvant

Veteran Member
Joined
Oct 12, 2010
Location
Europe
TDI
2004 Audi A4 Avant 1.9TDI Quattro, 2002 VW California, 1998 Jetta TDI (Sold 6/16), 1997 B4 Passat TDI, 1993 Eurovan Weekender 1Z m-TDI conversion (Sold 5/12), 1992 AHU powered B3 Syncro Wagon
Keep the pepperpots until you have run the bbs long enough to have cleaned them once or twice while it's somewhat cool out, which is probably a warm day for you. Your fingers will freeze
True, the Pepperpots are perhaps some of the easiest wheels to clean. I'll be washing the cars inside the garage in the winter and I'll be picking up a wheels brush specifically for these wheels. So far I really like how they look, I was going for a more OEM+ look.
 

AKAvant

Veteran Member
Joined
Oct 12, 2010
Location
Europe
TDI
2004 Audi A4 Avant 1.9TDI Quattro, 2002 VW California, 1998 Jetta TDI (Sold 6/16), 1997 B4 Passat TDI, 1993 Eurovan Weekender 1Z m-TDI conversion (Sold 5/12), 1992 AHU powered B3 Syncro Wagon
If that f150 wasn't lurking in the back round this would be like a shot into 1997 when that car was only 5-6 years old.
Thanks! I'll try and stage a pic that is more period correct.

So I'm still chasing down a idle pulse and bucking at part throttle. I'm hoping cleaning up the VSS ground might help. I unplugged the VSS and the issue seemed to go away.
 

GTiTDi

TDIClub Enthusiast, Macht Schnell! Vendor , w/Busi
Joined
Oct 18, 2010
Location
3 Spruce st Wareham, gateway to Cape Cod Massachus
TDI
'91 GTI CJAA swap,'02 Jetta wagon ALH swap, '03 GTI 1.8T rally car, '03 Sprinter 3500
I unplugged the VSS and the issue seemed to go away.
Double triple check your Cruise control connections/ clutch and brake switch operations if this is the case...you can manually test them w a multi mete or w vagcom...
 

AKAvant

Veteran Member
Joined
Oct 12, 2010
Location
Europe
TDI
2004 Audi A4 Avant 1.9TDI Quattro, 2002 VW California, 1998 Jetta TDI (Sold 6/16), 1997 B4 Passat TDI, 1993 Eurovan Weekender 1Z m-TDI conversion (Sold 5/12), 1992 AHU powered B3 Syncro Wagon
Ok, now this is interesting since my CC has not worked. I'm not getting a signal from the brake switch, even though I know the brake switch is good. In VAG-com I can see that the brake signal to the ECU says that it is constantly "On." I get a flashing GP light after 5 minutes of continuous driving.
Should I just follow the wires from the brake switch?
 
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AKAvant

Veteran Member
Joined
Oct 12, 2010
Location
Europe
TDI
2004 Audi A4 Avant 1.9TDI Quattro, 2002 VW California, 1998 Jetta TDI (Sold 6/16), 1997 B4 Passat TDI, 1993 Eurovan Weekender 1Z m-TDI conversion (Sold 5/12), 1992 AHU powered B3 Syncro Wagon
Been traveling for awhile so I have some messages to respond to. The girl is running strong. Turning heads and making me smile every moment. Some recent pics below. The best reaction is quote, "What is that f*cking car?". And , "Is that a diesel Passat??" And having old and young people come up and ask, "Is that car real?" Hard to know what to say sometimes. Standard responds had been that it's a car VW should have made.


 

hatman30

New member
Joined
Oct 17, 2014
Location
Bristol
TDI
VW T4 with AHU /mk3 engine and mods
Hi there, any chance you'd be able to give me the part number for the AC Compressor mount that u uses please as I'm struggling to get one for my AHU?
Thx D
 
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