TDI conversion

[sdewitt at stx.rr.com]

You forgot to mention what type of fuel filter to use. Gasoline cars have evaporative emissions which largly prevents moisutre from collecting in the fuel tank from condensation. Diesel's do not have this, in many instances, like my 84 rabbit, the tank is vented directly to the atmosphere, which causes water to condense inside the tank due to temerature changes. Gasoline fuel filters will not remove water, however the diesel filter will, and some have a spigot which will allow the user to drain the water.

Water + 26,000 psi in a diesel injection pump will quickly destroy it.

----- Original Message -----
From: Eric S <scirocco at vintagewatercooleds.com>
Date: Friday, October 22, 2004 11:49 am
Subject: Re: TDI conversion

> 
> *raises hand*
> 
> Well, not *done* doing my own, but currently own a converted car. 
> (see sig).
> 
> David Marshall (the guy who does the harness conversions) is hands 
> downone of the most knowledgeable guys in the wiring department of 
> theseengines.  There ARE some considerations that can make it 
> difficult or
> easy.  Last I heard though, David is refusing to do harnesses for 
> anythingbut Vanagons now, so you'd be on your own adapting the TDI 
> harness to your
> car.
> 
> Contrary to what someone else posted, you don't have to change the 
> fuellines or tank...just need to find a filler neck with large 
> enough hole, or
> cut out (as some have done) the stock restrictor in your filler 
> neck. 
> Remove the stock fuel pump and just plumb some straight through 
> line in
> place of the pump/accumulator, add a fuel filter, rip out all 
> stock gas
> emissions equipment, etc.  Its not as terrible as it sounds, cause 
> you are
> mostly removing uneeded items.
> 
> Now, obviously, you'd need to start with a 4cyl car, since the 
> trannieshave different bellhousings...though there were some 5cyl 
> TDIs (the AEL
> code from euro audis) for sale here in the states recently.  Cost 
> of a
> good used 4 cyl TDI is around $2000-2500 including everything you need
> (later TDIs will require aquiring the instrument cluster, key and key
> reader from the donor car...anti theft system).  Easiest motor to 
> swap is
> the 96-97 Passat and 97-98 Jetta engines, engine code AHU.  Those 
> lack the
> anti-theft annoyances of the later engines, and have a few different
> things on them that make them  more reliable in my book (normal 
> wastegatedturbo instead of a VNT, non-Bosch MAF).
> 
> So, as for your cost question, that all depends on if you want 
> used or
> new, but ranges from $2000 (low side, high mileage used 4cyl) to $5500
> (new 4 cyl or used 5 cyl).
> 
> Wiring:  You are not on your own, lots of good people over on
> "TDI-conversion at yahoogroups.com" to ask about wiring, including David
> Marshall posting there daily.   But, that will be one of the 
> harder things
> of the swap, just have to be careful and work through the harness 
> in a
> methodical manner and hook things to the right places on your harness.
> 
> Gearing, someone else mentioned this.  This could be a large issue for
> you.  You need to find gearing that keeps you at 3000 rpm or so 
> while at
> highway speeds in top gear.  The TDI redlines at 4500, and isn't 
> makingdidly for power after 4000.  Many of the vanagon guys just 
> put taller
> tires on to make up gearing...don't know how feasable that would 
> be on
> whatever Audi you are considering the swap into.
> 
> Lastly, performance:
> 
> Yes, there are lots of easy things to do to get more power.  Chip 
> alonewill not get you to 130hp...close, but not quite.  My Corrado 
> is running
> the euro .205 injectors (from 110hp motor) and the 11mm injection pump
> from a US Automatic TDI....getting around 130-140 with that combo, no
> chip.  Able to out run VR6 and G60s with ease, while getting 47mpg
> average.  Learning to shift at 3000 rpm is a little difficult, but 
> resultsin best mileage and acceleration.
> 
> -- 
> Eric
> www.vintagewatercooleds.com
> 
> 1981 Scirocco S (TDI swap project)
> 1988 Audi 90 Quattro
> 1990 Corrado TDI
> 1991 Cabriolet (2.0 crossflow 8v project)
> 
> David.Payne at brinksinc.com said:
> > If anyone has done a TDI conversion on a gas engined car?  What 
> kind of
> > cost and electronic headaches?  What rpms is the TDI happiest?  
> I've found
> > a vanagon specialist in Canada that does conversion harnesses.  It
> > wouldn't
> > be hard to equal the 130 hp that my 10v 90q has and should get 
> 40+ mpg
> > plus
> > 170+ lbs/ft.
> > Feel free to contact me off list.
> > Dave.
> >
> > _______________________________________________
> > quattro mailing list
> > quattro at audifans.com
> > http://www.audifans.com/mailman/listinfo/quattro
> >
> 
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