By now, the GLI was beginning to feel like a complete car; however it lacked the power an enthusiast demands. To fill this void, Max looked to friend and mechanic Arturo Ortega to squeeze more horsepower from the 2.0 16v. The car received forced induction thanks to a Garrett hybrid T3/T4 turbo. The custom kit included an HKS blowoff valve, Turbonetics wastegate, Samco Sport hoses and a Spearco front-mount intercooler. Arturo also fabricated a custom exhaust manifold to mount the turbo and improve airflow.
Improving the fuel flow were 440cc Bosch injectors, a Ross Machine fuel rail and Automotive fuel regulator.
An ECU and harness swap completed the new configuration. The 16v originally came with a mechanical CIS injection system, but Arturo and Max updated to the digital Digifant 1 system. Sourced from a Corrado G60, it's more tuneable for this application.
With the motor conservatively tuned, it now offers a reliable 215whp. Max shifted focus back to completing the exterior. The front end was updated with Rallye headlights, but he reengineered them with smoked low beams and amber high beams from a Mercedes.
The interior received beautiful Recaro front seats trimmed in cloth. The rear seats were then swapped for a Corrado bench, which was reupholstered to match the Recaros.
For a sporty feel, the factory steering wheel was ditched for an Italvolanti. Providing subtle accents to the interior are Momo pedals and a Trimsport UK aluminum shift knob with a clever 16v emblem.
Next on the list was a host of Auto Meter gauges to monitor the engine's vitals, mounted on the A-Pillar and center console. The last upgrade was the headlining, which was retrimmed in black.
Although the Jetta was nearly complete, the exterior was beginning to show its age, so Max embarked on the final and most time-consuming task - a repaint. He decided to dismantle the car down to its shell. "I had to remove the doors, engine, hood, all the windows, interior, sunroof - the list goes on!" he explained. "Each part was painted separately using OE Tornado red paint. While the doors were apart, I had Audi 90 handles fitted."
Continuing the custom work, Max had the banana lights and hood shaved. A Mercedes side vent was then molded to the passenger-side fender to help chill the engine bay and simply look cool.
Before the paint was finally applied, Max sourced new seals, bumpers and fenders to give the car the appearance of being new off the dealer's lot.
Today, Max has aspirations for more performance and cosmetic tuning. Although it's already been four years in the making, he plans to continue the build by lowering the car further with a set of H&R coilovers. He's contemplating forged pistons and rods to provide more reliable boost, and also expects to remove the transmission in favor of a Corrado unit with a Quaife limited-slip.
While these newer plans may take time to accomplish, Max will continue showing his Jetta in California and Mexico. He'll also be busy directing his car club, Westside Mexico. The group was formed in 4/01 with only four members. Six years later, there are 35 members who meet weekly, thanks to Max. And with this level of enthusiasm, we're certain this isn't the last time we'll see incredible project cars made in Mexico.