My 91 GTI 8 valve to B4 1Z TDI swap

I used B4 upper airbox pieces to make my hybrid A2/B4 box

I love your build! Question: did the Passat pedal assembly DBW setup fit and clear without any issues? I know there are a few holes needed in the firewall, one stud ground off, and some extra bolts on the Corrado pedal assembly, but I have never seen the Passat stuff in person. Looks like you had to so some minor firewall mods as well - just not sure if it's the same stuff.

Thanks man likewise! Nice choice of car! I actually have some questions for you regarding lifted Mk2's, I saved the B4 TDI suspension with this in mind, although for my Jetta Coupe..

The Passat pedal assembly is nearly identical to the mk2 assembly minus the fact that it is dbw and hydraulic clutch release. There was only one stud that I had to add to the Mk2 firewall in order to have it bolted in 100%. Oh I had to tweak the slot at the end of the column and egg the column mounting holes but other than that it fit perfectly.

What did you use for a cluster? I still have to upload a lot of pictures, modified mk2 cluster bezel included..I have been too busy having fun this summer!

GTiTDi said:

Thanks man likewise! Nice choice of car! I actually have some questions for you regarding lifted Mk2's, I saved the B4 TDI suspension with this in mind, although for my Jetta Coupe..

The Passat pedal assembly is nearly identical to the mk2 assembly minus the fact that it is dbw and hydraulic clutch release. There was only one stud that I had to add to the Mk2 firewall in order to have it bolted in 100%. Oh I had to tweak the slot at the end of the column and egg the column mounting holes but other than that it fit perfectly.

What did you use for a cluster? I still have to upload a lot of pictures, modified mk2 cluster bezel included..I have been too busy having fun this summer!

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I am running the MK3 cluster - just hacked out the stock MKII cluster supports. Not pretty - but it works.

I hope to have a ton of MKII/MKIII lift info posted on my website soon. I have posted the info so many times on various forums that it's time to get it all in one place. I just want to get pics of all the modded parts up so it's real easy to follow. Lifted coupe huh? that sounds AWESOME!

And I'm glad to hear that about the Passat pedals - that's probably going to be my recommendation to anyone attempting this. the Corrado DBW mod is a bit more involved.

Lift a coupe......wait did I hear that right? Ok I'm glad I snagged it

I cant stand the whole "Hella Flush" Stanced Dubs trend..broken oil pans are not a badge of honor! I like Rally cars better so there you go!

gtitdi said:

i cant stand the whole "hella flush" stanced dubs trend..broken oil pans are not a badge of honor! I like rally cars better so there you go!

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win!!!

I actually agree. I was poking fun at Frankencar, for buying my coupe in his town before he had a chance to get there

Rebuilding the 1Z for more reliability and power. ALH pistons, porting the head, converting to 7mm stem valves, dual springs, dressed rods...basically improving some of the weak points of the 1Z design..not going for all out power but will hopefully be ready for it when I decide to tune it further!

take a look at this thread before you drop the pistons in:
http://forums.tdiclub.com/showthread.php?t=210044

G60ING said:

take a look at this thread before you drop the pistons in:
http://forums.tdiclub.com/showthread.php?t=210044

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cool, thanks Frank. Going to re-use the stock rods, and check the aim of the squirters..I have already dressed the lips at the top of my bores

Head is back from machine shop...updated to 7mm stem valves, 5 angle valve seats, mild porting, ABA dual spring setup with 034 motorsport valve springs...

ALH pistons, NRP rings, Kolbenschmidt bearings, and dressed and polished connecting rods..entire assembly balanced...took these pics a while ago but finally uploaded them...

boost gauge location


my new EGT gauge..will even have a warning buzzer and light once I am done with it!

my new lift pump

I love your build, i basically left my motor stock for now, getting it to fit and making everything fit was first, i will spend money on the motor when i finish my build, money goes like water and it seems my bank account seems to always have zero in it....great job keep it going

vw_nut said:

I love your build, i basically left my motor stock for now, getting it to fit and making everything fit was first, i will spend money on the motor when i finish my build, money goes like water and it seems my bank account seems to always have zero in it....great job keep it going

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Thanks! I have been trying not to spend too much money on this project, but that is much harder than I thought...

I was checking out the recent photos of your Caddy, looking good on those modernized snowflakes!

Diesel Lift Pump

http://farm8.staticflickr.com/7002/6491108565_85a47c5fc1.jpg

GTiTDi, what's the operating pressure of this little pump? Price etc...? I'm thinking about one for the truck's long, elevated fuel line run. Wonder how your IP readings will be before and after.... or if you expect them to change much.

It is 4-7psi. They recommend it be mounted within a foot of the fuel supply. Mine is mounted behind the passenger side strut tower, works fine.
Cost around 65.00 at AutoZone

Hi GTiTDi,
I discovered your thread and was really impressed with your project! I live in Rockport and have a place in Marstons Mills. Perhaps we could get together sometime. I have a rather stock 2000 TDI Golf that I love. I commute to Wilmington during the week and enjoy the 50ish mileage. I also enjoy working on my car, but when I get stomped, there's Keith Harley in Chelmsford for help.
Happy Motoring!
Larry

P.S. Love the pretty girl clinging to the VW emblem!

2000golftdigls said:

Hi GTiTDi,
I discovered your thread and was really impressed with your project! I live in Rockport and have a place in Marstons Mills. Perhaps we could get together sometime. I have a rather stock 2000 TDI Golf that I love. I commute to Wilmington during the week and enjoy the 50ish mileage. I also enjoy working on my car, but when I get stomped, there's Keith Harley in Chelmsford for help.
Happy Motoring!
Larry

P.S. Love the pretty girl clinging to the VW emblem!

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Thanks Larry!
P.M. me if you are planning to be on Cape! We have bi weekly get togethers in Hyannis if you are interested in talking VW's and diesels! Also If you are in the area and need anything taken care of on the car don't hesitate to contact me as well. The image of the girl on vw logo was found online, I am pretty sure it is supposed to be Betty Page!

GTiTDi said:

I still have to upload a lot of pictures, modified mk2 cluster bezel included..

Click to expand...

Well after quite a hiatus, I finally uploaded some shots of my modfified mk2 cluster bezel. The mk3 cluster fits nicely in a mk2 dash with the right modifications. Done wrong and they look like scheisse. The solution is often just doing a mk3 dash swap, but unless you have a mk2 with power windows it isn't a viable option. I like to be able to roll my windows up and down with the door shut. Most mk3 dash installs don't allow enough clearance for the cranks!


I used a spare mk2 glovebox (broken) as a source of material for adding to the bezel. I added material all the way around.

Sections of glovebox to adapt Mk3 cluster to Mk2 dash

Good looking job!

How about more details of the glovebox to dash adapter? That would be a timesaver for those of us who'd rather follow your example than reinvent the adapter!

I looked at the bottom picture a little more… Did you just extend the shell? By how much?

Does this mean that the cluster fits deeper into the dash than the Mk2 cluster fits? If so, how much deeper?

Many thanks!

clyde said:

Good looking job!

How about more details of the glovebox to dash adapter? That would be a timesaver for those of us who'd rather follow your example than reinvent the adapter!

I looked at the bottom picture a little more… Did you just extend the shell? By how much?

Does this mean that the cluster fits deeper into the dash than the Mk2 cluster fits? If so, how much deeper?

Many thanks!

Click to expand...

I don't want to take the fun away from figuring it out!

GTiTDi said:

I don't want to take the fun away from figuring it out!

Click to expand...

OK, OK, I'll dangle the gold bug from the limb of the oak tree by the light of a 3/4 moon…

clyde said:

OK, OK, I'll dangle the gold bug from the limb of the oak tree by the light of a 3/4 moon…

Click to expand...

It is clear what needs to be done when you start fitting it up, start by removing the mounting points for the mk2 cluster, and then fit in the mk3 cluster to see where to start trimming. The mk2 bezel needs to be widened and extended as not to block the edges of the mk3 cluster.

clyde said:

OK, OK, I'll dangle the gold bug from the limb of the oak tree by the light of a 3/4 moon…

Click to expand...

BTW nice Poe reference!

got any pics of your Saab intercooler setup?
I take it this replaced the stock B4/mk3 IC?

Crazy Hungarian said:

got any pics of your Saab intercooler setup?
I take it this replaced the stock B4/mk3 IC?

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Yes the stock inter cooler setup is only suitable for stock power levels. It was kind of a waste of time to modify the fender to install the side mount. I should have gone with a front mount from the beginning, but this has been quite the learning experience!



a mix of B4,A3 and SAAB intercooler pipes

The B4 intercooler pipe has just the right bends to clear the dipstick

The turbo outlet pipe from the B4 fit under the A3 intercooler>intake pipe well, used a coupler to connect to the B4 intercooler pipe

The former home of the side mount will house an additional windshield washer reservoir to supply a water/methanol injection setup

This intercooler pipe pictured is from a 93 Saab 9000...not the car the intercooler came from..that is a 2000 Saab 95..
I will update later with pictures of my modified mk2 fan shroud..had to ditch the stock fan motor..they are quite bulky...

custom slim fan pics

I forgot to post this video of my engine noise after melting number 1 piston. When I took the video I was trying to identify the sound...Happened after a long run at triple digit speeds, Stock teeny turbo and too much fuel, no egt gauge..ugh, I have learned a lot since then.
http://www.youtube.com/watch?v=EaGvALTuTmI&feature=related