BLACK FOREST INDUSTRIES ABA to1.8T MK3 ENGINE SWAP KIT

INSTALL GUIDE

*Please note – this is only a guide – for complete R&R engine procedures please consult appropriate service manuals

OVERVIEW

This guide will allow you to understand fully the nature of the work involved in the swap of a 1.8T variant engine into an ABA (2.0) equipped Mk3 (Golf/Jetta 1993-1999) chassis. Not all work is included and some variance will occur between different engine codes, but this will guide will explain what parts are necessary and what needs to be kept or changed from the donor motor as well as the chassis receiving the engine.

INSTALLATION – PREPERATION OF THE 1.8T ENGINE

Remove the stock ABA engine from the chassis and remove all accessories and their related brackets, pulleys and mounting hardware (please refer to service manual for details).

If you are using an external water pump 1.8T (AEB) all original ABA accessories will bolt directly to your engine

If you are using and internal water pump 1.8T (all engine codes post 2000) you will need to retain the 1.8T accessory bracket:

o The ABA alternator and Power Steering pump will bolt directly onto the 1.8T acc bracket

o To retain AC from the ABA a spacer will need to be fashioned for the mounting bolts as the 1.8T AC compressor has a wider mounting flange

o AC lines will need to be slightly bent to allow for clearance and install of the oil filter – this MUST be done delicately as the lines can be damaged.

o An additional acc belt roller PN 06B-109-244 – available separately on our website with correct 40mm bolt and nut for this application.

o This roller is installed using and extra boss on the Alternator, below the stock pulley. The belt used is a 6PK-1165 Here is a diagram for the belt routing for the internal water pump 1.8T with AC and the extra roller:

Remove the ABA rear motor mount and bolt it directly to the 1.8T block.

Both ABA front motor and transmission mount may be reused – we do recommend upgrading to one of our BFI stage engine mounts (stage depends on shore hardness desired)

If you plan to reuse the 020 transmission, you can reuse your stock clutch, but we recommend an upgraded 210mm clutch and flywheel – Stage 2 or 3 for this application.

If you are adding an 02A/02J, further modification, and a G60 style flywheel will be required.

EXHAUST

We recommend installing the engine with the turbo and exhaust manifold already mounted to the 1.8T.

You will need a downpipe – you can choose one of the two options available on our website - http://store.blackforestindustries.com/mk31cokitad.html or you may fabricate your own.

Any Mk3 Cat-back and Cat-section / test pipe will work with this application – thought we recommend a 2.5” system (or larger for bigger turbo applications)

WIRING

While there is technically no “wiring” of this kit – there are several steps that involve extending existing wires or swapping sensors. Unless otherwise noted reuse all existing ABA senders/O2 sensors/Electrical connections. Here are the connections that will need to be extended – we recommend extending these wires after the engine has been installed so wire lengths can be measured properly.

Lengthen the throttle body connector harness. Lengthen the distributor hall sensor connector harness. Lengthen the Air Intake Temp Sensor connector harness:

o This temp sensor must be changed to the early AEB style sensor as it uses the same plug as an ABA – PN# 058-905-379 – available in our add-ons section.

Reuse the MK3 MAF housing and element

INSTALLING THE KIT COMPONENTS

Installation of the kit components is straightforward, but here are few diagrams and tips to make installation easier:

THROTTLE CABLE BRACKET

The included throttle cable bracket bolts to the font of the 1.8T intake manifold – there is a boss with a through hole and one threaded hole in between cylinders 1 and 2 on the intake manifold. The bracket bolts to those holes as pictured below. You will re-use the stock ABA throttle cable retainer and bolt it to the bracket also as pictured below.

The kit requires the use of a VR6 throttle cable PN# 1H0-721-555AA – which can be sourced from a donor car or is available directly from our site.

DISTRIBUTOR INSTALL

The installation of the distributor is very simple – first remove the cam position sensor from the timing side of the cylinder head (this procedure is listed in any 1.8T equipped repair manual).

Once removed the BFI 1.8T swap distributor may be installed. Before installing we recommend removing the distributor cap for easier access. Please note that this distributor is “keyed” to the shape of the cam slot – it will only fit properly in one direction, requiring only minimal timing adjustments, if any. Note the picture below, showing the key of the distributor:

Once the distributor is sitting flush to the head you can install both M6 socket head bolts using an M5 hex key bit as shown below (please note that the image depicts a simplified version of the distributor for reference). Make sure that the timing mark (only on one side) is facing towards the front of the vehicle:

Once the bolts are in place the distributor can be tightened down. This distributor allows for timing advance and retard *WE STRONGLY RECOMMEND THAT YOU NOT ADJUST TIMING FAR FROM STARTING MARK – ENGINE DAMAGE CAN OCCUR. Line up the front bolt with the timing mark as a start little if any adjustment should be necessary.

Turning the distributor base clockwise retards timing, while turning it counter clockwise advances timing.

PLUG WIRE INSTALL

The included plug wires connect to the stock coil location and attach to the Distributor as follows:

For this kit we recommend the use of BKR7E NGK spark plugs – with a gap of .25. We have pre-gapped plugs available for purchase through our store.

COOLING SYSTEM

The cooling system components will vary depending on your choice of engine code:

If using an early external water pump 1.8T (AEB) you will need to swap the MK3 water pump to the 1.8T block and use the ABA crossover pipe and cooling hoses.

If you use an internal water pump 1.8T you will need to modify the ABA cooling hoses:

o The upper ABA radiator pipe will need to be modified by cutting out the “Y” section and installing a MK4 plastic “Y” connector (1J0-121-087, water distribution pipe)

o If you keep AC – the AC water temp sensor will be installed in this “Y” connector.

o If you discard AC install with plug (357-121-140, cooling hose flange plug)

o The small nipple on the “y” will be connected to the coolant reservoir - all of these parts are available in our “add-ons” section

The lower ABA radiator hose will need to be cut in the middle and extended with a 6” piece of 1.125” aluminum pipe – also available through our store.

Use a MK4 2.0 AEG coolant flange for the side of the 1.8T head (06A-121-132, cooling hose flange)

o Install the ABA ECU water temp sender into this flange The coolant feed to the turbo will need to be connected to a T-fitting

installed in the hose from the bottom of the coolant reservoir and the flange on the side of the 1.8T head.

FUEL SYSTEM COMPONENTS

This base kit uses all factory Mk3 chassis fuel delivery components, as well as all 1.8T engine fuel delivery components. That is to say, use the stock ABA fuel pump, connect the fuel lines and keep the stock 1.8T fuel rail and injectors.

Install supplied 3.5 bar fuel pressure regulator into stock 1.8T fuel rail.

SOFTWARE CHIP/MODULE INSTALL

The software installation should be the last step completed and not undertaken until the car is ready to run. Before starting, make sure that the battery is disconnected completely!

Start by peeling off the rubber weather stripping and removing the 4 phillips head plastic screws from the passenger side cowl cover. Once those screws are loosened pull them off with a pronged removal tool.

After removing the cowl, loosen the ECU bracket by removing the 10mm bolt and 10mm nut that hold it in place. Once loose pull the ECU out of the cowl.

Once removed from the cowl disconnect the ECU connector by pulling the release slide.

With the ECU free – remove the ECU bracket (#3) via the two Phillips head screws it is attached with.

Using a T15 torx driver remove the 4 screws at the connector end that hold the ECU in its case. Pull out the ECU to reveal the green board.

Locate the square, socketed PLCC 44 chip on the ECU – this is the engine chip. To remove it you may gently pry on each side alternate to the squared corner of the chip. We recommend using a PLCC removal tool (available for less than $5 at radio shack or on Amazon).

Once the chip is removed, replace it with the chip AND module (the chip sits in the module). Installation is reverse of removal, and once the car is ready to start, reconnect the battery, start the engine, and let the car idle up to temperature. Perform a leak check procedure and make sure that all bolts and nuts are tight before attempting to drive – once the car is up to temperature, you are ready to enjoy your newly 1.8T swapped MK3!