mk3 95 jetta glx vr -> turbo diesel

[fuslit]

Since I got shot down via the wife on a turbo diesel passat, I'm seriously thinking about putting the turbo diesel motor that I have into my daily mk3 jetta glx. (since it's pre-ob2)

The motor I have was supposedly freshly rebuilt but I'm going to go back over it and clean a few things up. It's not going to be stock but will it have enough power to push the car (and bike rack) at an acceptable speed?

Non standard things that I have and most likely will be on it
- Raceware head studs
- GTD injector nozzles
- Bigger turbo
- Large front mount intercooler
- 16v passat o2a trans with a tdi 5th gear
- rebuilt turbo diesel pump with some mods to push rpms, and more fuel.

Things I'd like to put on it/keep.
- Serp belt kit from 2.0
- metal head gasket
- abs
- air-con

future?
- 1.9 turbo diesel head
- frybred wvo tank?
- bio-diesel

Things I know I need:
- Tdi fifth gear set
- flywheel (will a tdi flywheel bolt up I've got one?)
- starter
- 2.0 serp belt conversion & alt (unless I can use the vr's)
- Downpipe and Exhaust

What else would I need to change / swap to get this to work (the air-con might be a project but figured I'd keep it since it still works...)

Thoughts, suggestions, threads of people who've already done this?

-Todd

[flapjack]

if you mean serp belt kit from a gas 2.0, it doesn't fit. It hits the injection pump

on my 1.6td I used the a.c. and alt from a 2.0 gas on a 1.9 td serp bracket and crank pulley
you also need a different pulley for the water pump and power steering

heres the serp faq
http://vwdiesel.net/phpBB/viewtopic.php?t=9599

[jtanguay]

bleached bora sells 5th gears.  http://www.boraparts.com/

[fuslit]

Thanks for the tips, I have started compiling a list of things I want/need to do this swap.

-Todd

[flapjack]

some random stuff:
For the solenoid on the injection pump, the wire that fed the ignition coil works well
For the fuel pump in the tank: keep it in place for the fuel gauge float but disconnect the power to the pump and run lines directly to the bottom of the tank.
Or you can use it as a lift pump, there is a thread somewhere about how to cheaply reduce the pressure with a couple of hair pins and a bottle of ketchup.

Throttle cable: mk2 1.6td cable didn't fit the mk3 gas pedal, cable for 2.0 gas was too short, I got a 1.9TD cable from my cousin in Europe. I tried ordering it from a place in Canada, but they sent me a clutch cable instead.

Don't forget an EGT gage

If you can't get the right serp setup used from Canada, theres a good place in PA that has 1.9td stuff, I don't remember the name

glow plugs: I mounted the relay from the mk2 on the strut tower and a rigged a button on my steering column.

[Dr. Diesel]

I'm guessing you're using a 1.6L
win_equipTD on here has a 1.6L in his B3 passat. It motivates along well enough, but feels heavy with a load of passengers.
I'd recommend putting the smallest turbo you can find on it.
A K03-003 would be perfect. What a 1.6L in a heavier car needs is immediate spool up. It'll make the engine feel bigger, having full boost by 1500rpm. I believe QuickTD has run his at an intercooled 18 psi for some years now. My syncro's K03 is set to 14 psi, no issues. A T2 or K14 would be second best, but stay away from T3 k24 unless you're wishing to live with the irritations of running a laggy car with a 1000rpm powerband.(unless you're running a Giles Pump)
For a daily driver, keep the turbo small!
My syncro will accelerate up a steep hill from 2000 rpm in 4th gear! That's the K03-003.
Steal the glowplug system from an A2 and install it. The black, two-pin temperature sensor will plug right into your coolant flange, and the relay's cheap. I even went so far as to wire in an LED on my gauge cluster for glow plugs.
I ran out of time, and didn't install the cold start advance system. It wouldn't have been difficult though. Instead, I've just bumped the pump's lever to the advance position and left it there. She's a little more rattley at idle, but no harm.
Keep the fuel pump circuit intact and drop the pressure.
here's how I did it:
http://vwdiesel.net/phpBB/viewtopic.php?t=12727&highlight=fuel+pressure

[fuslit]

I'm guessing you're using a 1.6L
win_equipTD on here has a 1.6L in his B3 passat. It motivates along well enough, but feels heavy with a load of passengers.
I'd recommend putting the smallest turbo you can find on it.
A K03-003 would be perfect. What a 1.6L in a heavier car needs is immediate spool up. It'll make the engine feel bigger, having full boost by 1500rpm. I believe QuickTD has run his at an intercooled 18 psi for some years now. My syncro's K03 is set to 14 psi, no issues. A T2 or K14 would be second best, but stay away from T3 k24 unless you're wishing to live with the irritations of running a laggy car with a 1000rpm powerband.(unless you're running a Giles Pump)
For a daily driver, keep the turbo small!
My syncro will accelerate up a steep hill from 2000 rpm in 4th gear! That's the K03-003.
Steal the glowplug system from an A2 and install it. The black, two-pin temperature sensor will plug right into your coolant flange, and the relay's cheap. I even went so far as to wire in an LED on my gauge cluster for glow plugs.
I ran out of time, and didn't install the cold start advance system. It wouldn't have been difficult though. Instead, I've just bumped the pump's lever to the advance position and left it there. She's a little more rattley at idle, but no harm.
Keep the fuel pump circuit intact and drop the pressure.
here's how I did it:
http://vwdiesel.net/phpBB/viewtopic.php?t=12727&highlight=fuel+pressure

You are correct, 1.6td motor (sorry should have specified)

I do have an EGT gauge and will be installing it.

I've got a fairly large turbo at the moment I"ll take your recommendation for a smaller one into consideration.

Thanks again for the thoughts on the project I'll keep you posted with progress.

-Todd