TFSI or TSI swap??

[Bumblebee58627]

How difficult would it be to swap a 2.0 TFSI or FSI engine in a 2007 1.6 panel van ?
what work would go into such a swap? mountings, etc?

[NZDubNurd]

mechanically, it's piss easy - jusy find the bits and poke them in. I have a 3.2 VR6 from an R32 in my Touran.

Electronically... time consuming! you need compatible modules and coding etc, PLUS all the wiring changes. The R32 Touran conversion probaly only took 6 hours for the mechanicals, but prepping and studying wiring was hundreds of hours, then nothing too major to make the changes.

It's my 4th repower/conversion, and I found it OK. Not cheap though!

[Bumblebee58627]

Thank you

So if get a 2L crossflow something like a APK or ABA Engine and a management system it will be easy?
And what gearbox will work best? because the 1.6 revs at 4000rpm in 5th gear at 120km/h , which sounds high.

[dan@biali]

Never going to be easy! Mine took over 100hrs in wiring alone and I had given the garage a donor car. I'm still not 100% up and running as the gauge cluster is one of the trickiest parts to code correctly and not have warning lights on permanently.

[NZDubNurd]

Thank you

So if get a 2L crossflow something like a APK or ABA Engine and a management system it will be easy?

Never going to be easy!

Depends on your definition of easy, but there aren't too many who would call it easy!

There is a lot of reaserch to find compatibility issues.

Some guys have fitted a whole Golf loom etc, to keep it easy. I've kept the Touran looms, and fiddled what needed fiddling to match the R32. I've fitted the Golf cluster to the Touran, along with the ECU and ABS, so those 3 modules all think they are in the Golf, together, still.

The immo version have to match, the ABS has to be compatible with the drivetrain modules etc.

Using 1 whole donor car would be the sensible approach... but I used the engine and 4motion from a 8P Audi A3 3,2. trans from a mk4 Bora, ECU, CLuster and ABS from a mk5 R32 Golf. Plus a bunch of other crap that has to fill the holes - Audi TT driveshaft, with mk5 R32 outer CV, Golf 7 R airbox, etc, and a few random other parts from the VAG parts bin - it really is like lego, but you CAN dig a big hole that you dump money parts and time into, and STILL possibly end up with a pile of parts all crammed together, that doesn't go!

Trans wise, You'll probably want whatever came with the engine, unless you carry heavy loads all the time

I don't want to scare you off, but I don't want to cause you (or anyone) to destroy their car if they are unaware I've gone through phases of complete meltdown/panic, because this IS MY CAR... I'm driving my bright orange '72 Beetle every day while I'm sorting it out! and the Touran is really supposed to be for my Mrs! I don't think I'll really give it to her though

Stuff you'll have to deal with:






Let us know how you go and what you decide - it a VERY hard call to make!

[dan@biali]

This was the floor of the reception area at mdm for a while and the screen in the background has wiring schematics on it



The wiring inside the Caddy is in different positions more than anyone realised so modules had to be moved and even the bus bar is in a different place from Golf to Caddy. The entire looms had to be spliced which in the case of mine meant re-pinning a lot of the plugs

[NZDubNurd]

Haha! I love those pics!

mine was in the lounge, with hundreds of printed pages... and it only came out after my 3 boys were in bed, and had to go away before I went to bed. I had a year of planning before I made the jump.

[SimonR]

@dan@biali
Now you're going to give me nightmares tonight lol !


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[dan@biali]

It gave them nightmares. One of the guys dreamt the floor was covered in snakes instead of the wires and the other one thought he was being strangled by them.

[SimonR]

I can imagine that.

This is powerful voodoo we play with here !


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[Bumblebee58627]

Damn, those are some scary wires...
Are those for R32 engine swaps or Normal 8v swaps?

[dan@biali]

Mine is an Edition 30 so thats a MKV Golf GTi 2.0 tfsi 16v with the KO4 turbo.

[SimonR]

Mine is R32 mk5 full loom....


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[shanky887614]

cant be that bad it will just be time consuming, im doing a bit of panel building from time to time and there are a lot of cables

**

[Bumblebee58627]

I can understand all the wiring for the newer engines, but a normal mk4 golf motor swap wouldnt be that bad, the engines look and work about the same doesnt it?