Completed Project 93 Explorer TDI Swap

[Rick]

A few small things but nothing too exciting…

Been driving it everyday to work (hard to drive the GTI to work when it’s muddy half the time). Got about 3500 miles on the swap now. Upgrading to 4.56s helped a lot with drive-ability. It’s been working great!

Fuel gauge still gets stuck when it’s filled up. Then works again around a half tank when I hit a bump. Seems like the float is getting caught on the return line on the pump. One of these days I’ll either drop the tank or cut an access panel to fix that.

Heater hoses developed a couple small leaks at the clamps. Put some higher quality clamps on and no more leaks.

Ended up adding a vacuum reservoir a month or two ago. The geometry change of the turbo is vacuum controlled. At higher RPM the vacuum pump can’t keep up on its own and would cause a very noticeable stutter. Basically the turbo would switch back and forth between its two profiles very quickly. Reservoir fixed the problem and the geometry change is nice and smooth now.

Still need to add an oil pressure gauge. The factory VW sensor and wire is in place, but the wire was removed from the ECU plug when the harness was built by the last guy. Either need to figure out how to pin it back into the ECU plug so that the Scan Gauge can read the signal or need to add another gauge on the a-pillar. If I go the route of an external gauge, the remote oil filter adapter has an extra port to add another sensor.

Overall it’s been a pretty flawless swap. Fires up with no issues even at 15 below. Drives great and the turbo noises put a smile on my face every day!

That's great to hear. It was definitely an ambitous swap. I'm glad it worked out for you.

 

[BKennedy]

I forgot, what size tires you running? I'm still thinking this swap would go good with my 700R4, 5.13 gears, Atlas II and 35" tires. I would probably install a doubler while I was doing the engine swap.

 

[timtimtimajim]

I forgot, what size tires you running? I'm still thinking this swap would go good with my 700R4, 5.13 gears, Atlas II and 35" tires. I would probably install a doubler while I was doing the engine swap.

I’m running 33s. So I think if you had a similar build on the motor, 35s and 5.13s would be pretty similar. A doubler with all the low end torque would be a lot of fun.

 

[timtimtimajim]

Looks like I got the fuel gauge issue sorted out. Didn’t feel like dropping the tank so, cut an access panel under the rear seat. Found a $20 nibbler that attaches to a drill. Made cutting the hole super easy and no sparks.

Looks like the float was getting caught on the power wires for the pump. Rerouted them in a different spot and used a few extra zip ties. Couldn’t get a picture since I didn’t pull the fuel lines off or the pump hanger out all the way. Made a quick patch panel and sealed with butyl tape and self tappers.

 

[RangerX]

Found a $20 nibbler that attaches to a drill.

Have a link to that nibbler?

 

[timtimtimajim]

Have a link to that nibbler?

Here you go! https://a.co/d/fbeuWen

 

[Josh P]

For anyone wondering the maximum rated cutting thickness, 1.6mm is 14 gauge.