jollyGreenGiant
Veteran Member
Though I would post up a little information that I was not ever able to determine prior to embarking on the project...
In the last week I swapped a TDI drivetrain into a 96 GLX wagon. While doing so I wanted to install a Webasto heating unit. It turns out with a little fabrication work, the B4 chassis is a great fit ( at least so far ).
For one thing, the 96 Passat has the 5th injector plumbed in, remove that and feed the Webasto unit's pump with that line, the location of the factory 5th injector pump is on the side of the air box with a nice rubber grommet, the Webasto pump fits into the grommet and functionally works great in that same location as the actual heating unit mounts below the air box where on the VR6 a charcoal cannister belongs. Below are some pictures to show the cutting that was required to make it fit:
BTW: The unit takes some time to initially purge all the air from but the coolant system still burped fine and expelled all it's air, the unit is heated to coolant temp along with the engine, the heat output from the core seems unaffected so far but it's not winter yet and it's not pumping heat into the system yet.
Original sheet metal:
Test fitting the unit:
Area primed and undercoated: ( the large cutout below the framerail is for the pump wiring loom )
Top cutout area:
Top with air box on: ( I had to remove the "ribs" molded on the bottom of the box.
With the unit and fuel pump/lines installed:
Coolant lines at the firewall ( I helped myself to the VR6 heater core hose and it worked out perfect for the application )
Coolant lines going through the bottom of the airbox ( yes through, why not? )
There will be a second part of this... ( I have to deal with the wiring and antenna for the remote, the visible LED and other such things... )
In the last week I swapped a TDI drivetrain into a 96 GLX wagon. While doing so I wanted to install a Webasto heating unit. It turns out with a little fabrication work, the B4 chassis is a great fit ( at least so far ).
For one thing, the 96 Passat has the 5th injector plumbed in, remove that and feed the Webasto unit's pump with that line, the location of the factory 5th injector pump is on the side of the air box with a nice rubber grommet, the Webasto pump fits into the grommet and functionally works great in that same location as the actual heating unit mounts below the air box where on the VR6 a charcoal cannister belongs. Below are some pictures to show the cutting that was required to make it fit:
BTW: The unit takes some time to initially purge all the air from but the coolant system still burped fine and expelled all it's air, the unit is heated to coolant temp along with the engine, the heat output from the core seems unaffected so far but it's not winter yet and it's not pumping heat into the system yet.
Original sheet metal:
Test fitting the unit:
Area primed and undercoated: ( the large cutout below the framerail is for the pump wiring loom )
Top cutout area:
Top with air box on: ( I had to remove the "ribs" molded on the bottom of the box.
With the unit and fuel pump/lines installed:
Coolant lines at the firewall ( I helped myself to the VR6 heater core hose and it worked out perfect for the application )
Coolant lines going through the bottom of the airbox ( yes through, why not? )
There will be a second part of this... ( I have to deal with the wiring and antenna for the remote, the visible LED and other such things... )
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