Engine Specific Info and Questions > mTDI Mechanical TDI Conversions

The B3 Variant mTDI build....FINALLY!

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RabbitGTDguy:
Well, its finally here. I am getting around to finally being able to build and install the mTDI motor in my b3 variant. I hope this thread serves as an informative one. I'm well versed with the mTDI's and have been here before, some of you may remember the GTD thread...here...
http://vwdiesel.net/phpBB/viewtopic.php?t=1956&highlight=gtd
or
http://forums.tdiclub.com/showthread.php?t=129127

It has been a little while since I have updated that one, but I'll continue to do so over the summer even though the bulk of the activity this summer will probably be with the b3 in the name of the rising gas prices and my desire to really get the car converted by fall. The mk1 mTDI is running as great and "mad" as ever and is anxiously awaiting its 02a CTN trans install which I'm just waiting to save money for a nice clutch to go with it and then it can go in. She'll receive complete bodywork and paint though this winter...I hope.
A pic for reminders...



and of course...



AH...but on to the b3. The car that the swap is going into...



The Passats motor is a 16v and is slowly approaching 160k. Not bad for the 16v. The CIS-E motronic fuel system has never been tweaked with and i have fairly mild mods on the motor itself. A chip, wires, a nice TT exhaust, etc. Nothing major though. It runs well and gets decent mileage but I'm really itching to get that TDI in there.
The mTDI for this build will not be as all out as it was for the mk1. I won't be going with shaving the pistons, ceramic coating (though...that has crossed my mind) or crazy turbos, intake manifolds, AWIC setups, etc. like I did here. The idea with this build is to keep it as clean stock looking as possible similar to the AAZ setups that were offered in the b3.

However, the motor has already surpassed the mk1's build in displacement. I have to say that none of this would be possible without the help of STIG (on TDIClub) whose former b4 motor is the base on which my motor is being built. It was indeed a tired motor and when I took it into the shop it had to have some work done...which I'll explain as it follows here but again THANK YOU Stig for the great wedding present! I hope to keep in touch (and will PM you after I get this posted).

Onward...
Here is how the motor started out...stock 1z base...








Time for next post...

Joe

RabbitGTDguy:
After tearing the motor down I found that the stock cylinder bores just weren't going to cut it which meant a trip to the machine shop and my having to source new pistons. I was able to pick up a set of .5mm OS Nurals for a great price and the pictures tell it all about the quality. No chinese junk here...





the block itself was hot tanked, honed and is ready for its paint here soon at this point.


Had the crank polished and the rods resized since it is going to be a daily and I really want the "best" I can out of the motor. Besides...do it once...and do it RIGHT.




The machine shop that I used did an excellent job and I'm impressed with them for yet a second time around (as they had the mk1's block originally when I did that build).

Here are some other parts I've been sandblasting and detailing in the meantime that are ready to go.


You can see the euro 'cable' clutch there and the Mk1's 02a hiding, ready to go at the bottom of the pic. For now, i'll be retaining the passats hydraulic clutch but have a line on another euro cable clutch setup if I want it.

Additionally...AAZ specific parts will include AAZ b3 wiring main harness (so I can sell the current as a complete swap...), AAZ b3 cluster, airbox, downpipe, etc. all hiding in the box...



I will be using another CTN trans that I have for the car as well. Turbo wise, I'm going to use the older 1.6 IDI / 1.9 IDI turbo/intake manifold configuration and going with a T3 or a K24 from that era of car. I have a K14 in hand but don't think I'll be happy with the max boost I'd be able to pull from it.

Additionally, I'm building another Cummins 4bt pump for the car...

I just need the time to finish it.  Thanks TIN TIN

I think I picked the passat for this swap because of how great the car has been. I love the ride of it when it is on the road...loaded especially. the car runs bilstein HD's on all four corners and neuspeed springs. Has Hella DE's that I have made my own heavy wiring harnesses for and relayed as well as a number of little bits and additions that I have added in the past few years. I can't imagine not having the car and its been great and really (besides body parts) is easy to find parts for since it shares so much in common with the mk2 and mk3 chassis. Even the b4 of course underpinning wise. Eventually I'd like to add "Syncro" to the title here...but that is when I find a decently priced swap!

So, I'm at the point where I am waiting for other funds to buy the needed seals, hardware, etc. to assemble the motor. I'll be detailing the block in the next week or so and starting in on the head as well. I only believe in putting quality into my builds and that includes parts. I am not "rich" by far, so enjoy spending good money on "the good stuff" where needed. I'm looking to run about 18psi of boost and I'm going to go with a G60 intercooler setup until I figure a different one out (or modify the G60 cooler) in the spring of next year. i'll be running bosio nozzles...probably the .216's I have to start with but would like to work up to the PP764's or maybe 520's...we'll see. The pump currently is utlizing a 12mm head which i've been seeking out a more sedate 11mm unit...but I may run the 12mm and just keep my foot off the "go" pedal as much.

So, I think that is a good place to start. Alot of info there and I'm sure I'll think of more. I should have started it a while ago...but just haven't gotten there until now. I'm a graduate student...finishing up my degree and find this is the first night I've really had to do this...

I hope it will be a great...and informative build. Target....FALL!!!

Joe

rallydiesel:
That Rabbit is awesome.

snakemaster:
nice Passat that will make a nice Mtdi and a good all round car look forward to see more posts  :D

Gearhead:
Bad ass rabbit.  Those pistons are art.  If I had the dough, I'd just buy one to look at.

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