1991 B3 Passat Wagon AHU Syncro Swap

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AKAvant

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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
bbob203 said:
Why did you have to use a b3 vr6 condenser?
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Due to the radiator outlet locations I ended up needing to use the G60 radiator. The VR6 condenser fit the G60 rad better and I was also swapping in a complete R134 AC system so it made sense to use a R134 sourced condenser. My plan is to find a B4 TDI cross-member, radiator and condenser and eventually swap them in.
 
oil_me

oil_me

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Woodstock, NY
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Black '99 Jetta, Glacier Blue Audi 80 Quattro TDI
AGK pump

Quote:
Originally Posted by samuraitd
im using a 2.8 lt pump on an ahu motor, is there anything special i need to know about timing it?

I'm using this pump also
http://www.vwdiesel.net/forum/index.php?PHPSESSID=6bc5fc2a37af3e03f111494548e2e522&topic=9598.15
in my application and have been playing with the timing for months. It's set now @ .91mm since December. It starts beautifully with an IDI GP relay. Set @ 1.00mm; it has lots of power but narrow rpm range and is much noisier. Mine ran well down to .83mm; very quiet and smooth power; but it was a little smokey. I'll turn mine down when I have an intercooler to help deal with the smoke. Search for "mTDI pump timing" for more info. For the stock AHU e-pump I have read that .78mm is optimum static timing. (quieter) If you turn the timing down you may have to bump the idle up.
Rich
 
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B

Big Daddy Roth

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1992 B3 Syncro 1Z, 1992 B3 Syncro AAZ, 1992 B3 Syncro AAA
AKAvant said:
So a slight issue arose last night as I was installing the radiator and coolant hoses. It seems like the front of the engine is sitting lower than is ideal and is causing the AC compressor to press on the lower radiator hose. I know the B4 TDI uses a different front engine mount and clip but does anyone know if there is a mount I can use with a B3 16v front clip that will raise the engine up higher? Or could I add some sort of spacer?


Thanks!
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You have to use the combination of bracket, mount, and front cross member from either the B3 or the B4. It sounds to me you need the 16v mount and bracket.
 
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Big Daddy Roth

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1992 B3 Syncro 1Z, 1992 B3 Syncro AAZ, 1992 B3 Syncro AAA
I just realized the rad hoses for a 1z/aaz b3/b4 should be on the other side.

It looks to me you have the 'deeper' lower rad support. You need a AAZ/VR6 rad. The G60 rad is smaller and needs the 'higher' lower rad support.

If you use a B3 AAZ/vr6 rad, you need aaz B3 hoses. If you use the B4 AAZ/vr6 rad, you need B4 hoses. (The lower rad hose fitting is the difference here).

You can use a B4 1Z rad, but you will need the lower rad support for it.

16V radiator will not work with anything that has a serp belt. The AC compressor is in a different position on a V-belt 16V, which allows for the 16V hose to go where it needs to go.

Upon closer inspection, I think you have the right front mount set-up.
 
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Big Daddy Roth

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1992 B3 Syncro 1Z, 1992 B3 Syncro AAZ, 1992 B3 Syncro AAA
Oh,

B4 rads will fit in a B3, but you have to trim the bolts that drop down from the top of the upper rad support. B4 rad bolts wont fit in a b3.
 
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bbob203

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b5.5v
I used my 16v radiator with mtdi b3. It would make the purists cringe but it was a 2 dollar fix. bassicaly I used 1z waterneck and hose I chopped the hose into 2 90 degree elbows and put a piece of copper pipe in to make up the difference and sealed it with 2 german hose clamps. Furthermore I added 2-3 hardened washers between front engine mount and bracket slightly tilting the engine back gaining the clearence need. I plan on getting proper stuff at some point but for now it works.
 
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Starkey

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MB
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1992 B3 Syncro Passat TDI GT2256v winter beater
i love this build, i also have an ahu b3 syncro tdi and it is a lovely relationship haha
i am running a g60 rad and coolant pipe just fyi but no ac
 
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AKAvant

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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
Thanks for all the info on the radiator setups, I'll be back in AK in July and I'm determined to have it on the road by the first days of August. I'll be sure to document the final work.
 
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AKAvant

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Everything is installed. Just finished the intake piping. Going to triple check everything, prime fuel lines, fill oil and coolant and start her up tonight!
And new metal injector lines are next on the order list.
 
G60ING

G60ING

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No TDIs Currently, I have an R36 Corrado. I've had an ALH Corrado swap, AHU Corrado swap and 2003 TDI Jetta
I love the look but if you are springing for new injector lines then please get black hose to replace the blue :)

If you are buying the prothe lines let me know what you think about them. I bought them and decided to not use them.
 
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AKAvant

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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
Haha, yeah blue was the only color high pressure hose I could get locally. High quality stuff but only came in blue. This is my first gen intake setup so I'll be tweaking it as I break in the car.
 
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AKAvant

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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
As she sits now, just need to run and get distiller water.
 
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AKAvant

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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
Made my own relay position #12 glow plug jumper out of a 167 fuel pump relay. I relabeled and used the old cover.

 
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AKAvant

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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
So she's alive.....sorta.
Cluster shows mileage and time but done of the warning lights show up when the ignition is turned on. The starter engages fine.
The only code I'm getting is:

00626 - Glow Plug Indicator Light (K29)
31-10 - Open or Short to Ground - Intermittent

Could this be due to the fact that I'm using a JB ECU from a '98 Jetta instead of a FA ECU that this harness usually comes with?
 
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AKAvant

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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
So it runs!! Idles and revs smoothly! Will post video as soon as I can upload it.
The cluster is dead though except for the mileage and clock. MFA isn't working either.
Any ideas on why this is? Going to scan codes again after she ran.
 
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AKAvant

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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 posted a thread about this over on the B4/A3 forum but thought I'd repost it here to keep some continuity to the thread.
But I'm going to chalk this one up to the exhaustion of being in the garage 12hrs a day for the last 5days.
I never had a D-connector from a TDI Passat and forgot to grab one from my old wiring harness. I started tracing the schematics and realized my mistake.
I found a D-connector from my 1992 Syncro Passat donor car and plugged it in as best i could and voila, everything worked and all the codes were gone!
 
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AKAvant

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It runs! 2nd or 3rd start. My funny walk/run is due to almost every square inch of floor space being covered with parts/tools.
 
G60ING

G60ING

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No TDIs Currently, I have an R36 Corrado. I've had an ALH Corrado swap, AHU Corrado swap and 2003 TDI Jetta
Sweet, now drive it to my house and hand me the title :)
 
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AKAvant

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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
Haha, I'll think about it.....
 
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AKAvant

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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
Wired in the power windows and power locks, was great to see all the windows move up and down. Anyone recommend a good lubricant for the window mechanism and window guides?
Also installed the E-code and fog lights (relayed with a Eurowire.net setup). Now I just need to get rid of the DRL function so I can run the city-lights.
 
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AKAvant

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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
Finished up all the door wiring and vac hosed. Cleaned up and mounted the fuse box along with making a radio harness for a wagon.
I need to see a chiropractor after all this...
 
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AKAvant

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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
So my front blinkers don't work. The blinkers will light up with the headlights on but only then. The rear blinkers work, they just blink fast as if a bulb is out. I'm using a B4 headlight harness and switch with a relay, and Hella E-codes. I'll look over the schematics tomorrow but was curious if anyone had any ideas?
 
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Scott_D

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Blackstone MA
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1996 Passat 1999.5 Jetta
does this problem happen with battery hooked up or with a trickle charger?

MY B3 did the same thing and I had to change the battery charger from 2amps to the higher amperage setting
 
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AKAvant

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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
So before returning to Hawaii for work I finished up installing the black leather door cards, dash, and carpet. It's a mix of tan/black interior pieces that I'm sure I'll be swapping back and forth until I'm satisfied. Also installed one seat. My front seats are from a Drivers Edition MKIII GTI. Wish they were heated though! I was going to mount the wheels and take a quick test drive but I didn't have long enough lug bolts to account for the 8mm front and 15mm rear spacers I'll be running. The pepper pots won't fit over the G60 brakes without spacers. I'm not sure if the 15" RML Snowflakes will either.



 
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AKAvant

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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
She's almost ready to roll. Tomorrow she leaves the garage for the first time in 2 years. Damn these projects take longer than planned!
Syncro badging and RMLs installed.


 
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