1991 VW GTI TDI Swap

GTI TDI Swap at Bonneville Salt Flats

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  • Owner:
    • David
  • TDI Engine Swap Video:
  • Performance:
  • Fuel Economy:
    • Fuelly
    • Best Tank: 78.494
    • Worst Tank: 51.546
  • Web Forum Threads:
  • Engine:
    • TDI (AHU)
    • Bored out to 81.5mm
    • Balanced and Blueprinted
    • BHW pistons with Swain-Tech Ceramic coating
    • SciTex Trick Titanium wrist pins
    • Rosten Rods
    • Ported and polished
    • TT dual valve springs
    • TT titanium retainers
    • Swain-Tech ceramic coating on head and valve faces
    • Colt stage 2 cam
    • 11mm Injection pump
    • Lightened and balanced intermediate shaft
    • TDTuning custom MAFless tune
    • Race 520 Injectors
    • Borg Warner BV43 turbocharger from PD170
    • AFN Exhaust Manifold
    • AFN turbo oil feed line
    • AFN Turbo oil return line
    • AFN turbo support braket
    • Westach EGT probe - 1/4NPT 1/8 probe
    • FRANKENBUILT 304SS 2.5" Downpipe
    • TT 2.5" Downpipe back
    • Mufflerectomy
    • Caddy eshaust hangers (chain type)
    • 1992 MKII Air Box Bottom with Corrado SLC Inlet tube
    • Stock MKII Air Filter
    • Corrado SLC Airbox Top
    • MK3 Jetta VR6 MAF housing - cut in half
    • 2007 Jetta 2.5 intake pipe
    • FRANKENBUILT 304SS turbo inlet pipe
    • FRANKENBUILT Aluminum 2.5" intercooler plumbing
    • Rallye Golf intercooler
    • Street Toys 2.5" race pipe
    • PD130 intake manifold
    • ABF Alternator Setup with Bosch 90A Alternator
    • Power Steering Deleted
    • High Temperature thermostat - 92°
    • Early Cabroilet aluminum thermostat housing
    • 630mm euro passat (with tow package) radiator - to fit rallye golf intercooler
    • Passat 16v dual radiator fans
    • MANN+HUMMEL ProVent 200 CCV filter
    • FRANKENBUILT valvecover to delete CCV puck and feed CCV filter
    • FRANKENBUILT 3 Bar MAP Sensor
  • Suspension/Drive train:
    • MK3 K-Frame, fulley seam-welded and reinforced
    • Manual steering rack
    • MK3 Golf CL Tie rods
    • Mk3 TDI transmission (CTN Code)
    • BoraParts 6-speed kit with .622 6th gear
    • Peloquin limited slip differential
    • Late MK4 02J Shift box, tower, and cables
    • Audi TT shift weight/lever short shifter 
    • Neuspeed B4 Passat VR6 front sport springs (210 in-lbs) 
    • Modified (2 dead coils cut out) Neuspeed B4 Passat VR6 rear springs (185 in-lbs) 
    • Bilstein HD shocks and struts 
    • Ground Control camber plates 
    • MK3 VR6 A-Arms
    • MK3 VR6 Knuckles, blueprinted, lightened & shot peened
    • MK3 VR6 Hubs with ABS rings removed
    • Mk3 VR6 CV shafts with GKN joints
    • R32 front A-Arm bushings 
    • 19/25mm DE front sway bar 
    • Shine Racing rear sway bar
    • FRANKENBUILT rear stub axle adapters
    • MK4 rear stub axles
  • Brakes:
    • 25mm Master cylinder 
    • 300x25mm custom 2-piece RacingBrake front rotors
    • Porsche Boxster Calipers
    • FRANKENBUILT 7075-T7 Aluminum front caliper carriers 
    • MK4 RacingBrake drilled and slotted rear rotors
    • MK4 rear caliper carriers 
    • MK4 aluminum rear brake calipers 
    • USP Motorsport Stainless braided brake lines with black sheath
    • Akebono Euro Ceramic brake pads
  • Wheels/Tires:
    • 15x7 et48 Team Dynamics Pro Race 1 Wheels with a 5mm spacer 
    • 185/55r15 Pirelli P7 Cinturato All Season Ecoimpact LRR tires
  • Stereo:
    • Sony Xplod 
    • Blau Punkt speakers 
    • Sub in the trunk
  • Interior:
    • Hella Rallye steering wheel (By MOMO)
    • Rebuilt non-A/C heater box and firewall block plate
    • European passenger side deep non-A/C under-dash pocket 
    • European CE2 driver side under-dash pocket
    • Dash modded for MK3 TDI Instrumetn Cluster
    • 42DD Radio delete Gauge panel (3 VDO Vision Gauges: Boost, EGT, Oil Pressure) 
    • Stainless Golf GTI door sills
    • Hella smoked time-delay dome light
    • Corrado pedal assembly (Modified to accommodate DBW)
  • Exterior:
    • Fender lips rolled for clearance
    • Core support modded to fit Rallye Golf intercooler
    • FRANKENBUILT MKII Aero Wipers
    • Fiat Marea Weekend Estate rear wiper on a small spline pre-89 hub
    • Porsche 944 Door handles
    • Mercedes G500/G55AMG Headlights on FRANKENBUILT adapters with 35W 4300K HIDs
    • Clear inner driving lights with 50W 4300K HIDs
    • Rallye Tails wired with full rear harness sourced in German junk-yard
    • Genuine Wolfsburg front plate
    • 61MPG rear plate
    • European late MKII "Golf GTI" badge
    • MKIII Golf GT "TDI" badge
    • 97+ Jetta trunk catch pin
    • MK3 Cabriolet trunk latch
    • MK3 Golf Trunk stop rubbers
    • MK3 hood stop rubbers
    • MK3 Golf Hatch struts (Don't let it hit you in the face on the way up!)
    • MKII Diesel hood insulation
    • Diesel fuel tank with Ventectomy
    • Cabin air filter option
  • Misc:
    • Corrado VR6 front cross-member
    • Seat Toledo full front belly pan
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