JIGSAW 2015

Bigfella ,, not much too update really just fettling a few teething problems after shakedown and getting ready for her respray. i actually used a 2008 fabia 1.9 vrs ecu and engine loom to get her running and recoded the ecu to match my A2 so the immobiliser works as it should , i used an fsi fuel pump relay and wiring using a golf tdi tank sendor and pickup with fuel pump as the fsi fuel pump is too high a pressure for diesel. Nagah, Thankyou , was a mission to make but not as complicated as my first set of boost pipes , soo many angles and bends lol, 0.7mm stainless was wee bit too thin and had couple hairline weld failures during testing and shakedown and was losing boost so redesigning those with slightly thicker 316 stainless now

Few more photos of engine and gearbox mounts and front crash bar Half welded up for trial figment of the fmic and bumper figment , engine build , one off stainless GTB manifold , drive shafts cut down to correct lengths joiner machined over sized so shafts heated and plug frozen to join then tig routed and fully welded

its the same flywheel just newer , part number superseded

045105273 is from a newer engine 2008 , still compatible as its from the bms 1.4 tdi , its also advisable to replace the flywheel bolts as they come with thread lock applied N 90206103 hexagon bolt M10X1X19,5 x 6

If you do go ahead with the conversion to smf make sure you leave the alloy spacer out do not refit as not needed !!

Nyhahahahhahahaha that tickled me i like that saying haha trailer queens , I have several A2s and they all get used as my daily driver or family and friends borrow as they do from time to time , just retired my fsi well parked her up at mothers for a few months while my 1.2 tdi is stretching her legs again until i finish my final few tweaks with my intercooler and some wiring then my 1.9s off for weighing and an appointment with VOSA to be checked and then my log book would be updated with her new weight and engine capacity and on to shake down once she's through her mot

045 105 243 C https://audi.7zap.com/en/rdw/audi+a2/a2/2005-248/1/105-105010/#7 item 7 there is no need to change pulley it seems, i cant remember now why we changed pulleys as several yrs ago when we did the first conversion from dmf to smf

I’ve always used a second hand flywheel from a AMF donor engine I also used the amf vibration dampener pulley from the donor engine as presumed they were different but on the Elsa parts diagram it shows the same dampener pulley is used on all three variants the amf bhc and atl but I’d suggest double checking yourself just to be 100%

Thankyou that’s appreciated Nagah. yes for fun as you put it as im a bit of A2 addict, but imagine she would be my main daily driver and cover the most miles but they all have there own merits and characters and always swapping between my A2s

045 105 269 flywheel AMF,BHC my prefered clutch kit for a remapped tdi is the uprated Sachs Performance Clutch Kit - 3000951092-S otherwise the Valeo, luk rep set or standard sachs clutch kit are good options 02A 141 180 A guide sleeve 012 141 741 retaining spring 02A 141 777 B ball stud examine and replace if any wear 02J 141 719 C clutch operating lever 085 311 113 shaft oil seal

Thankyou yes I had to make custom engine and gearbox mounts and also made the main engine holder by the camshaft in two pieces so it can be disassembled for cam belt changes , if not the whole engine would need removing , I shall add some more photos and of the mountings although it was trial and error and many tweaks with a prototype until it fitted satisfactory with clearance all round the engine bay.

No problem at all if you need any more just ask my advice if you have the Tdi 90hp is to throw the dmf away and fit a AMF flywheel and dampener pulley on the end of the crankshaft and use the amf clutch kit , I have fitted 4 of these now replacing the dmf and know of another 2 owners who have gone this route and to be honest there is little difference in layshaft vibration and the amf clutch would be much better and longevity too as they can last 200,000 miles plus , if you do go this route just leave out the alloy spacer between the engine and gearbox

Only numbers I could find on the dmf also a photo of what could happen if you continue running with a faulty dmf

I have a few atl dual mass flywheels and could take some photos for you tomorrow, personally I tend to junk the dmfs and convert to solid mass flywheel as much more reliable as seen too many blown atl engines with conrods through the block from faulty dmfs

Thought I’d share my 1.4 90hp engine conversion I purchased a 1.9 ARL engine which had low mileage 78,000 which I tore down and had the crank and Conrods lightened and balanced and bores checked and lightly honed. Reassembled with Ned shell bearings and piston rings , cylinder heads been fully ported and polished with completion valve guides and multi angle seats , GTB 1756vk conversion on one off stainless manifold with EGT sensor , completion mild race camshaft , unrated black hydraulic lifters , smf conversion with uprated clutch wearing a 02m six speed gearbox Cupra R brembos brake set up with vented rear discs , rear anti roll bar , monroe reflex dampers all round with weitec -25mm sports springs , seat sport fmic cut down to fit available space , fabia vrs radiator , Audi TT Quattro front hubs which widens the wheel base with adjustable top mounts to make changes to castor and camber angle , one off custom length driveshafts , lower crossmember reinforcement bar. Webasto , Audi TT coolant pump for webasto telestart as you can imagine there’s not much room left in my A2 engine bay and although a very very tight fit everything’s in and has clearance and allowing for engine and gearbox movement. To do list & retrofits wiring sideguard , fis , rear pdc , tow bar , headlamp washers and winter pack heated mirrors and screen washer jets front crash bar and fmic mounts

My own take to an updated front bumper I used none fog light grills to fill in the sides and a Audi A4 sport grille cut down to size , originally I plastic welded the grille into my A 2 bumper but decided for longevity to make the grill overhang the bumper on the sides to stop the cracking issues on the joins.

Thank you for the photo and advice , although appreciated it's slightly different with the 6 speed gearbox , it's the larger bearing carrier that sticks out on the end cap that fouls , I will try and get better photos as this was just a googled image of an undertray but think as you say my only option is to cut a hole out for clearance , after reading many of the posts of the 6 speed conversions I find it strange I can find no mention of this issue either , so may help others once resolved

My FSI has a 6 speed gearbox conversion by CKR , up until now it has never had an engine under tray fitted , having fitted one today I've found the gearbox side upstand that bolts to the chassis rail with the 10mm nut fouls on the 6 speed end cover of the gearbox , I've found you can not fit the upstand on the under tray to the original stud on the chassis rail. Knowing several members have fitted the 6 speed can I ask if anyone else has had this issue and how they overcome this ? Ive debated heating the under tray up with a heat gun to try and reshape it around the gearbox end cap but knowing the under trays are a mix of glass fibres and abs plastic I'm unsure if this will work , my other idea would to cut out the section that fouls to give clearance and allow the upstand to be bolted up correctly , I've attached a photo with the upstand highlighted , Thanks in advance

I would like to do this retrofit myself using all the parts from a 2001 Tdi AMF donor vehicle I have into my 90 atl. frog999, can I ask did you get the webasto working correctly Id appreciate any advice or help and a wiring diagrams to aid in this if any one has the needed information. please and thank you in advance like. jigsaw.

Eine weitere Charge von Scheinwerferdichtungen wurde hergestellt, obwohl sie sich geringfügig von den Originalen unterscheidet. Sie decken jetzt nur die Seiten und die Oberseite des Scheinwerfers ab. Ich habe kürzlich ein paar Sets von TPS in Großbritannien gekauft Teilnummern 8Z0 941 192 A 8Z0 941 191 A hoffe das hilft Jigsaw

Another batch of headlight seals has been manufactured, although they are slightly different from the originals. They only cover the sides and top of the headlight now , I recently purchased a few sets from TPS in the uk part numbers 8Z0 941 192 A 8Z0 941 191 A hope this helps Jigsaw