You probably remember my '97 Golf CL with the early 1.6/1.9TD Frankenmotor:
Part 1 and
Part 2. The engine died due to v-belt slippage on the water pump. The engine was eventually sold to Dave aka 935racer aka Passenger Performance, who dynoed 192whp with a bigger turbo. I bought a 2006 Jetta TDI DSG and it bores the heck out of me (my wife also took possession of it).
I still think of picking up another IDI, but I'm an ECU tuner, TDI donors are becoming cheaper, TDIs tend to get better fuel economy, and they support more low-RPM torque out of the box, so I decided to go that route for my new daily driver.
I picked up a '96 Golf CL and a '98 Jetta TDI donor car.
Progress:Perform intake cleaningPerform TDI timing belt jobInstall performance camshaftInstall 400ft-lb torque clutchInstall TDI engine + transmission in GolfInstall 5 lug 11.3" VR6 brake parts with all new suspension bearingsInstall TDI pedal cluster in GolfInstall telescoping steering column in GolfInstall TDI wiring harness in Golf - almost complete. JS Performance takeover at this pointHook up coolant system and V belts- Install cruise control in Golf
- Install heated seats in Golf
Install coilovers- Make a high MPG / performance switchable-on-the-fly tune.
- Completely re-do interior
- Full body work + repaint
Pulling the 1.8L 8v 90HP gas motor from the Golf:
Pulling the 1.9L 8v 90HP AHU TDI from the Jetta:
Cleaned out this intake gunk:
My friend helping pull the dashboard. We removed the dash+rebar from both vehicles. The Golf's rebar was literally dripping with rust while the Jetta's was rust-free (factory painted).
The joy of wiring (as I progressed into it I learned that it's not really difficult, just time-consuming):
Due to my upcoming 2 weeks absence, I'm leaving the rest of the conversion to JS Performance: