1.6td into gas mk3

[flapjack]

Finally started this job

1994 2.0 Golf
(less motor)  



Moving into the 94 golf:

-1.6td and trans
-T3 off of a saab (oil and water cooled, not sure how the hell I'm going to do the water part)
-ebay 8v exhaust manifold
-G60 intake manifold
-shifter and pedal cluster (golf is auto!)
-Mk2 subframe, A-arms , knuckles, brakes etc - moving the whole mess over so i don't have to mess with making motor / trans mounts fit, and most importantly the axles
-intercooler: don't have one yet, but hopefully soon

Feel free to punch holes / point out flaws in my plans, I don't have any experience with swaps and even less time to get this done!

Done so far:
-Mk2 shifter box does not bolt up to mk3, It is too wide, so I trimmed the sides off and welded on some flanges to match the mk3 auto box

-Exhaust manifold from Ebay is , i think, designed for x-flow, had to grind a little to make it fit with the g60 manifold

--Turbo T3 from Saab 9000

-Didn't bother with the water cooling of the turbo, after some looking around, looks like a lot of kids are just pluggin' the water holes. As long as i don't beat on it before it gets warm and let it cool down when i park, should be ok.

-The turbo exhaust outlet ( downpipe flange ) has a tapered stub on it which makes it tougher to fabricate a d.p. flange.  To avoid that, I got the saab downpipe and cut it after the first elbow.  It's a little smaller dia than the 2 1/2" I'm going to weld to it, but its a nice sweep that goes further than 90 deg, so it should get me away from the shifter linkage.

-Clutch cable: mk3 pedal doesn't hook up to mk2 clutch cable
Got a mk3 clutch cable but had to drill out the mk2 clip that holds the end of the cable on the trans. to 1/4" dia

-Throttle cable: 2.0 gas throttle cable is too short and has wrong end on it, won't hook up to injection pump
mk3 pedal doesn't hook up to mk2 throttle cable. I ordered a throttle cable for a Canadian mk3 1.9TD, but they sent me a self adjusting clutch cable instead. I think because I'm in the states, their system farted and when I requested a part for a Canadian car...

-Radiator: mk3 radiator not as wide, but taller than mk2 diesel rad
Inlet and outlet are not in exactly the same locations, fan plug is different I'm going with the mk3 radiator, even tho its been patched with some kind of epoxy in a few places, I can't spend any more money before I see this thing start up at least.

[Patrick]

Can't you take the motor mounts off the gas engine and put them on the diesel? Save a lot of messing around if it will work. Works on mk1/mk2 swaps.........

[flapjack]

i THINK you're right, but i didn't even look into it too much because that doesn't solve the axle length problem
the mk2 axles are too short for the mk3 a-arms, so it seemed easier to swap the whole subframe assy with everything attached to it

[burn_your_money]

Why not use the mk3 tranny, axles etc? It'd be piles easier.

[flapjack]

its an automatic  

[burn_your_money]

I see. Well get a mk2 020 tranny and swap 100mm flanges onto it and use mk3 axles, should save alot of tinkering. I think the mk2/mk3 motor mounts are the exact same other then bolt pattern so that should save you some trouble.

[numbnuts]

G60 inlet? So i presume it fits and it is better than the stock manifold? I have one in the garage you see :lol:

[flapjack]

I'm using the G60 intake because I've read on this forum how terrible the stock one is. I figured why not try it. Its pretty cheap to get
The g60 intake mani won't fit with the stock exhaust manifold, so I got  one for a turbo gas 8v, that puts the turbo lower.
I pretty much copied what rabbitGTDguy  on his m-tdi (minus the sick m-pump and tdi motor )
the crazy rabbit post:
http://vwdiesel.net/phpBB/viewtopic.php?t=1956

[flapjack]

g60 intake manifold and ebay T3 exhaust manifold didn't fit on the first try.
I had to grind 4 or 5 spots on the intake to get the bolt holes to line up.
Grind off a little of the lip where the runner meets the head and a little of the material surrounding some of the bolt holes.



Turbo hit a runner, so  had to grind a bit off the turbo and a little tiny bit off the runner to get that to fit.   I'm using the internal wastegate, so I couldn't just rotate the compressor side a little.




To save money, I swapped the whole subframe with steering rack, tie rods, A-arms, brakes, and  mounts, but ended up using the mk3 steering rack because the spline isn't the same on the mk2 rack. If I'd know, I would have grabbed it off the donor car before I scrapped it.
So to keep my axles, I've got mk3 steering rack with mk2 tie rods
The only down side was the inadvertent upgrade to SOLID ROTORS ! !  
I'll move the mk3 rotors/knuckles over when i get the motor running



motor and trans are in. front motor mount from mk3 automatic fits fine.
 the turbo compressor outlet is hitting the heat shield on the fire wall, not sure what to do there yet. Otherwise, looks ok.  Looks a mess, but it's in