Quantum Performance Engineering

Conversion Guide TFSI - MK4 Do you want to fit a 2.0 TFSI engine to your Mk4 Golf Platform Vehicle?

This guide covers the fitment of 2.0l TFSI as found in the Mk5 Golf GTi and Audi S3 and others into any car based on a Mk4 Golf Platform with a DBW throttle and 1.8T, 2.0 8v, V5 or V6 engine. This includes: Golf GTi 1.8T/2.0 8v, V5, V6 4Motion and R32 (not AGU engine code) Audi A3 and S3 (not AGU engine code) Audi TT 1.8T and V6 Seat Leon 1.8T, Cupra and Cupra R Skoda Octavia 1.8T and VRs (not AGU engine code)

In all modern vehicles the EMS is highly integrated with the rest of the vehicle and the TFSI unit is no exception. In addition, its Euro 4 emissions level means it has many emission control functions and their associated diagnostic features that are not necessary or desirable on a converted vehicle The QPEng ‘Plug and Play OEM’ system for the 2.0 TFSI engine uses our own software within the original VW ECU to allow it to intergrate fully with the all the vehicle systems of the Mk4 while significantly increasing performance. In addition, the system retains full fault finding, logging and coding functionality and is fully compatible with Ross-Tech VCDS (VAG-Com) and other diagnostic tools (including main dealer VAS tools). In addition, you won’t get any rouge fault codes (e.g. from missing components) but genuine fault codes will be diagnosed and stored as normal.

As you would expect, the harness is also re-engineered to provide total ‘Plug and Play’ integration with project vehicle including the ABS, traction control, 4Motion/quattro systems (where fitted) and full dash functionality including trip computer along with OEM levels of look and fit. {mospagebreak title=Applicability of this Guide} Applicability of this Guide

The following information is intended as a guide only and no responsibility can be taken for loss or injury arising from its use. The BYD engine used in this conversion can be found in MK5 Golf GTi Edition 30. For the purposes of this guide the unit is identical to all other TFSI engines with belt drive camshaft found in Golf 5 platform cars. For a full list of suitable engine codes please see our FAQ section The conversion detailed was completed on a 2002 Golf 2.8 V6 4Motion. The install for other vehicles may differ. {mospagebreak title=Mk4 Golf 2.0 TFSI Donor Parts List} Mk4 Golf 2.0 TFSI Donor Parts List In order to make your TFSI conversion as cost effective and hassle free as possible it is important to ensure you obtain all the parts you need from the donor car. Likewise, although many breakers will supply you with everything from the engine bay for little or no extra cost, knowing what you don't need might also increase your bargaining power. For this reason we have included a list of parts, besides the basic engine, you will and won't need from the donor vehicle. This list applies to the fitment of an BYD engine into a 2002 Golf Mk4 2.8 V6 4Motion. The parts needed to fit other engines or for conversions into other vehicles may differ You will need: Qty Description 1 Engine control unit 1 Engine wiring harness 1Engine cover including MAF element 1Trunking from engine cover to front panel 1Lambda sensor before catalyst 1 Alloy turbo discharge pipe 1 Pipe to throttle including charge pressure sensor All original engine sensors and actuators are used apart from the downstream (catalyst monitoring) lambda probe and the purge valve. Knock sensing, wideband lambda sensor, variable valve timing and coolant after-run pump are all retained. http://www.qpeng.com

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The kit fully intergrates with the following Mk4 Golf systems: - Dash including trip computer, MPG display, MIL lamp etc - 4Motion/Quattro Haldex AWD system - Diagnostic system and OBD connector - ABS system - Traction control system - Radiator cooling fan control unit - Fuel pump - Fuel level sender - Airbags and control unit - Vehicle speed signal - DBW accelerator pedal - Brake and clutch pedal switches - CAN gateway and diagnostic module - A/C and climate control system {mospagebreak title=Vehicle Preparation & Additional Installation Requirements} Part 1: Vehicle Preparation & Additional Installation Requirements Ftting the engine to the Mk4 is a fairly straight forward affair. Each section of the guide deals with separate area of the conversion, detailing the tasks and parts needed. Preparation

Caution: On many MK4 platform vehicles a fuel pump prime event can be initiated by opening the driver's door. Ensure the battery -ive terminal is removed before beginning work on the fuel system! After disconnectiong the battery, draining all engine fluids and degassing the A/C system remove and retain parts as detailed in the tables below. Remove: Engine under tray (if fitted) Front bumper/grill Rad support/slam panel/headlights/radiator/AC Condensor Air box Front exhaust section including catalsyt Engine/gearbox (prop and driveshafts can be left in place Wiring trunking in engine bay Scuttle cover and windscreen wipers Engine harness ECU Carbon can and pipe work Battery and battery tray Engine bay harness (and send to QPEng) PAS pipe from rack to resivoir

Retain: Engine mounting bracket and bolts (1.8T only) Engine mount (1.8T only) Alternator/AC/PAS bracket (1.8T only) Alternator belt (1.8T only) Alternator harness (1.8T only) PAS Pump, pulley and pipework (not rack to resivoir hose) AC compressor and pipework Clutch and Flywheel (Unless uprating) - (1.8T only) Backplate (1.8T only or use TFSI) Transmission (1.8T only) Gearbox mounts and transmission securing bolts Transfer box to engine support bracket (4Motion/Quattro vehicles) - (1.8T only) Starter motor Starter motor bolts (1.8T only) Wideband Lambda sensor (6 pin) (post 2000 Vehicles only) Wiring trunking in engine bay Scuttle cover and windscreen wipers 4 pin coolant temp sensor

NB If using a V5 or V6 base car the retained parts marked as (1.8T only) must be obtained separately from a 4 cylinder vehicle since the V6 parts are unsuitable. {mospagebreak title=Engine Mounts and Transmission} Part 2: Engine Mounts and Transmission Engine Mounts The 1.8T engine mount and engine bracket fit the TFSI engine and ensure it is correctly positioned within the engine bay. Use of the TFSI engine bracket and/or mount will cause the engine to be incorrectly positioned. As stated in table on the previous page, use of a V6 base car will require a 1.8T engine bracket and engine mount to be aquired separately (see image comparing the 1.8T and V6 mounts below).

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The 1.8T engine bracket requires a small amount of trimming to clear the turbo compressor on the TFSI engine. Transmission For V5/V6 base cars many of the transmission parts are unsuitable so the 1.8T parts in the table below must be sourced separately. Part Part # Qty 1.8T 6 speed 02M gearbox Various1 1.8T 6 speed 02M Clutch and Flywheel (preferably uprated) Various 1 1.8T 6 speed 02M transfer box to block bracket (4 Motion/Quattro vehicles only) 02M409905 1 1.8T 6 speed 02M Starter bolts N908 271 01 2 1.8T 6 speed 02M Front bellhousing bolt N102 421 02 1 1.8T or TFSI backplate 038 103 645E 1 1.8T 6 speed 02M Flywheel bolts N90665001 5 TFSI S3 turbo oil drain pipe (if fitting FWD TFSI into 4Motion/Quattro vehicle) 06F 145 735D 1

The 1.8T clutch and flywheel can be retained. However, it is recomended that the both are replaced, preperably with uprated components, particularly in high power 4WD applications. Here we are using a 1.8T 02M Helix single mass flywheel and clutch kit. Fit the 1.8T clutch and flywheel using new bolts and torque correctly. Fit the 1.8T gearbox, including transfer box if applicable. Note that ome of the V6 bolts are not suitable (see table above)

Note that the transfer box to block bracket requires trimming in 2 areas to fit the block and clear the turbo support bracket. Also note that the transfer box to block bracket can't easily be fitted with the transmission install on the engine.

If a FWD TFSI engine is being fitted into a 4Motion/Quattro vehicle then the turbo oil drain pipe will foul the transfer box. A TFSI S3 type turbo drain must be sourced and fitted (see table above for part #)

Before reinstalling the engine and transmission complete the PAS hose work as detailed in Part 4. Reinstall the engine and transmission as normal. It maybe necessary to remove or reshape heat sheilding near the brake servo since space is tight in this area. {mospagebreak title=Ancillaries} Part 3: Ancillaries The following parts are required for this part of the conversion. For V5 and V6 base cars some of the ancillaries are unsuitable so the 1.8T parts in the table below must be sourced separately. Part Part # Qty 1.8T Accessory bracket (PAS, A/C, alternator)

06A 903 141 R 1 1.8T Accessory belt 06A 145 933 D (no AC) 06A 260 849 E (with AC)

1

1

1.8T PAS/AC Tensioner

06A 903315 E

1.8T Alternator Wiring

1J0 971 349 GM (no AC) 1J0 971 349 GN (with AC)

1

1.8T/V6 A/C Compressor (where fitted)

1J0 820 803 L (1.8T) http://www.qpeng.com

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1J0 820 803 K (V5/V6) 1 1.8T/V6 PAS pump 1J0 422 154 B 1 1.8T/V6 PAS pump pulley 038 145 255 A 1 Coolant temperature sensor blanking plug (A/C only) 357 121 140 1300mm 19mm alloy pipe (A/C only) - 163mm silicone 45 deg elbow (A/C only) - 1

When fitting the 1.8T accessory bracket to the TFSI some trimming is required to provide clearance around the FSI fuel rail.

An issue with vehicles fitted with A/C is the lack of space in the area round the compressor particularly where the pipe from the evaporator joins the compressor since the pipe wants to pass directly through the charge pipe that goes to the throttle body. On our V6 it was possible to make enough space for the pipe to pass behind the charge pipe by: Removing the secondary coolant temperature sensor on the inlet to the engine (it's not required) and replacing it with a blanking plug (see table above for part#). Replacing the stock 45 degree rubber throttle body elbow with a 63mm silicon one which is slightly longer and more flexible. Replacing the steel radiator bypass pipe on the front of the block with a length of 19mm aluminium alloy pipe. Removing the bracket that retains the electrical connectors under the intake manifold. At this point the 1.8T alternator wiring should be installed before installing the compressor, charge pipe, alternator and PAS pump. If required the A/C pipe can be tweaked carefully to provide some clearance with the oil cooler. On 1.8T vehicles the A/C pipe is a different shape so the approach detailed above may not be possible and a new pipe may be required.

{mospagebreak title=Pipe Work} Part 4: Pipe Work Coolant Pipe Work The Mk4 radiator can be retained and the TFSI coolant pipe work used unless specified below. Cut the TFSI bottom hose and then rotate and rejoin using a 32mm coupler and hose clips so it faces towards the bottom hose connection on the radiator. Use a piece of 32mm aluminium alloy pipe to join the bottom radiator outlet to the bottom hose. Manufacture new heater hoses from 19mm rubber hose, reusing the quick couplings to the heater matrix. Note that these are avaiable in 0, 45 and 90 degree angles - 45 degree seems to work best for both hoses.

The top hose requires a 32mm 45 degree bend silicone bend to be used at the radiator. The TFSI fill and degas lines can be fitted to the Mk4 header tank without modification.

PAS Hoses Almost all the V6/1.8T PAS hoses can be used on the TFSI engine. The only expection is the return hose from the rack to the fluid resivoir. This is bolted to the 1.8T/V6 engine and so fouls the TFSI turbocharger. Cut the steel PAS pipe close to the banjo fitting at the rack end. Run a length of 13mm fuel hose from the banjo to the bottle as shown in the images - it can be fixed to the chassis using the clips previously used for the lambda senor wiring. http://www.qpeng.com

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Vacuum Hose for Brake Servo Directly connect the TFSI hard plastic hose from the vacuum pump to the Mk4 servo hose close to the bulkhead See heater hose image above). {mospagebreak title=Intercooler} Part 5: Intercooler and Charge Pipes

Although the 1.8T vehicles are fitted with a modest intercooler(s) they are inadequate for the TFSI engine and should be replaced with a larger front mounted unit. Several commercially available 1.8T front mount upgrade kits are available which may be suitable for use with the TFSI engine. For our conversion we fitted a 550mm x 232 x 55mm universal unit behind the front bumper. Significant modifcations were required to the steel bumper bar and charge pipes and intercooler mounting brackets were manufacturered. Some bumper trimming was required but the unit is not obviously visible behind the bumper. The rubber intercooler pipe that joins to the alloy turbo discharge pipe that is mounted to the engine can't easily be used. However, trimming the first 5mm from the discharge pipe allows a 68mm silicon hose to be fitted directly.

Once the PAS pump has been fitted the alloy discharge pipe fouls the accessory belt. However it can easily be spaced away from the sump to provide sufficient clearance.

{mospagebreak title=Air Intake} Part 6: Air Intake

With some careful modification the TFSI Mk5 air intake trunking can be made to match the Mk4 slam panel. The following Mk5 parts are required: Air duct 1K0 805 971C 9B9 1 Air duct cover 1K0 805 965C 9B9 1 Air duct 1K0 805 962C 9B9 1 Ari duct 1K0 129 618BM 1 Screw for air duct N 909 868 01 2

First the battery tray must be moved as far towards the inner wing as possible. A small section of the cable trunking under the battery must also be trimmed. An existing spare hole in the chassis leg can be used for the front right battery tray bolt hole and the others redrilled to suit.

Remove the covers on the top RHS of the slam panel With the battery tray refitted offer up the slam panel and trim the panel and battery tray as required to allow clearance for the panel to fit properly. Offer up the Mk5 air trunking parts trimming as required so they sit under the top surface of the slam panel. Drill 2 x 6.5mm holes through the front panel and into the trunking. Position the holes so they lie under the cover when it is refitted, counter sink the holes by drilling an 8mm hole through the plastic (but not the metal beneath) so caphead bolts can sit under the cover. Use M6 cap head bolts and nyloc nuts to secure the trunking to the panel.

Trim the front panel covers to suit and refit

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Trim the battery cover to clear the intake trunking

{mospagebreak title=Exhaust downpipe} Part 8: Exhaust downpipe On 4WD models space for the downpipe is very tight but we managed to sqeeze in a 3" bore unit in.

{mospagebreak title=ECU wiring harnesses} Part 9: ECU Wiring Harnesses ECU Engine Harness The engine harness can remain installed on the engine throughout the conversion. However, if it has been removed reinstall as normal. Connections onto the engine are as follows: - 8 pin injector connector on front of engine - 6 pin connector on front of engine (cam position and rail pressure sensors) - Crank sensor - 3 pin grey on front of engine - 2 x knock sensors 3 pin green/blue on front of engine - Throttle body – 6 pin on throttle body - Air intake temp – 2 pin on intake manifold - Low fuel pressure sensor – 3 pin on fuel pump - Fuel pressure control valve – 2 pin on fuel pump - Charge pressure sensor – 3 pin on intake pipe - N75 valve - 2 pin close to turbo compressor - Diverter valve - 2 pin close to turbo compressor (K03) or near Throttle (K04) QPEng ECU Vehicle Harness Follow the QPEng Mk4 Golf P'n'P OEM kit installation guide for detailed instructions.Conversion complete!

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