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Discussion Starter · #1 · (Edited)
Ever since I drove a mk3 Jetta TDI I was amazed at the performance, something I had only experienced with the later Turbo Diesel Mercedes Benz 300 series from 87-90. I knew right away that it could be even more impressive if the heart of the beast was simply transplanted into a lighter skin...Problem was, the resale value of TDI's in any shape or form were understandably high..So I knew I might as well wait. In November I found a 96 B4 Passat TDI on craigslist for $2,000 dollars..and it only had 150K miles! I went and checked it out, it was rough around the edges but it ran beautifully so I talked the salesman down 500 bucks and drove it home, boosting all the way. I had picked up a 91 GTI 8valve with 130K on the clock for 500 bucks back in August that I originally intended on using as a parts car to complete my 86 Jetta Coupe...but then I realized how mint the GTI was, not to mention the fact that my first dub was a white mk3 golf, and the white mk2 started growing on me..its so clean. As soon as I figure out how to load up photos of the project I will, but unfortunately I am slightly e-tarded, not too net-savy:rolleyes:
 

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when you finish the car, if it comes up stolen, i DID NOT take it.. ;)

a mk2 TDI GTD is probably the finest car VW never built.. :mad:
 

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Discussion Starter · #4 · (Edited)
pictures finally

Well now I have a flickr account, which my photographer girlfriend suggested, who I should say gets most of the credit for the pictures..If I was with her back when I did my 86 Jetta coupe aba swap I would have documented that too. By the way, the pictures are way behind my work progress, mainly due to the fact that I am more used to actually just working on my stuff all the time rather than sharing the progress online...This is new to me..but without the beauty of the internet and technical forums I would have never had this conversion going along so smoothly. More so I should give my boss Scott, owner of Sports Imports of Cape Cod where I work credit for letting me use the nicely heated shop to do it all in!:thumbup::beer:


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Discussion Starter · #5 ·


good riddance PF gasser

Got the engine out of the Passat donor way faster than the much rustier GTI..was it due to the fact that the passat was a wolfsburg WVW..and the GTI is a 3VW...?
 

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Discussion Starter · #6 ·
passat B4 and GTI A2 front support

Here are a couple of pictures showing how similar the A2 and B4 front engine supports are..I already pressed out the inserts off the A2 support and will install them into the B4 TDI front support after I clean and paint the parts

 

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Discussion Starter · #7 ·
passat tdi harness

After doing my 86 Jetta Coupe OBD1 ABA swap, I was pleased to see how much simpler the B4 TDI harness is...Gotta love VW CE2!:thumbup:

 

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Discussion Starter · #9 ·
I now have the B4 pedal cluster installed. First I modified the firewall by welding a thin piece of sheetmetal over the two small holes where the clutch master cylinder goes through it. I neglected to take pictures of the process, but its pretty self explanatory. I didn't want to just make the large clutch master hole with out dealing with pre existing ones because I would have ended up with a jagged hole that would be hard to seal from the engine bay.

here is the pedal cluster from the inside

and a closer shot of the clutch master hole. I also welded an 8mm rear brake caliper bolt to the firewall for the pedal support bracket because there wasn't one there and I wanted it to be mounted rigidly..it is the stud seen at the top of the photo
 

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Discussion Starter · #10 ·
A weird thing about my particular B4 pedal cluster is this nut/bolt thing tack welded to the clutch pedal...it didn't affect clutch pedal operation of the donor car at all, and it seems like its purpose is to prevent the pedal from traveling past the over center..maybe to assist in clutch bleeding? I always use a bungee cord to assist the return of the clutch pedal when I bleed hydraulic clutches, but this is a good idea if it is the purpose.
 

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Discussion Starter · #11 ·
One thing I am not totally sure about is the shifter box install..I realize there is a hole to be drilled for mounting it to the tunnel but the thread I read about B4 passat tdi-mk2 compatibility said that the cable shifter box should bolt right in. The problem is that the cable shift box is more narrow than the linkage shift box..do I just have to make a support tab or plate to make it wide enough?

 

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Discussion Starter · #13 ·
already figured it out..crawled under there after I took out the subframe and got it up on stands...the shift box fits right in just gotta drill three new holes..I am fixing a lot of surface rusty areas before I bolt anything in so it is taking longer than a simple R&R..I will upload photos up the progress later on after work
 

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Discussion Starter · #15 ·
nice swap, where are you putting your IC? I put the stock MK3 in side mounted in my 88GTI
good question..I have been trying to fig out the best spot to mount an IC..I may have a set of biturbo S4 IC's to try out..a twin setup would be really cool..The IC that was on my donor Passat is a SAAB intercooler and I would have used it but the end tank is damaged from some dumb*ss who mounted it with a hose clamp..the clamp wore through the plastic from vibration and heat, and I don't wanna mess with trying to seal it with glue. I was also thinking about a cheapo FMIC...
 

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Discussion Starter · #17 ·
so after much cleaning and a little rust repair I finally have two coats of Alpine white on my GTI's engine bay..Takes a lot of work to redo the half-assed job done by the Puebla crew..found some rust that I'm glad to have taken care of now instead of crying later..


cleaned up and repainted my subframes as well
 

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Discussion Starter · #18 ·
broke a stud taking the down pipe off, so I had to drill it out. I am fabricating a downpipe that will hopefully flow better than stock, as well as eliminate the 5th injector bung. What a nice little turbo, bearings feel good too!
 

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Discussion Starter · #20 ·
getting things back together..bored a 2" hole by the HVAC intake for the ECU plug to pass through, fits really nice...adapted the passat headlight harness to fit the GTI, added an extra ground lead to chassis ground the headlight wiring, hopefully they will be brighter than the average A2...Got the subframe in tonight with a set of Audi TT bushings and polyurethane pivots pressed into A3 control arms..using a ZF A3 rack and the Passat B4 axles and spindles/calipers..the 8 valve base brakes are way too puny..going to use the rear calipers and stubs off the Passat as well before I ship it to the junk yard but stripping this stuff in the snow sucks, at least today was close to 40, its been around 25 for a while...


 
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