The B3 Variant mTDI build....FINALLY!

[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  

[Gearhead]

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

[fuslit]

Sweet!!! Can't wait to see the build

-Todd

[RabbitGTDguy]

Thanks guys...it will def. be detailed...i tend to do that. Its hard to keep up with sometimes! Usually try to keep this thread, a TDI CLUB thread and a local forum thread updated...started one on the vortex too...but i didn't really care about it when I did the mk1 one...so we'll see. I like sticking to my top 3

Joe

[jtanguay]

looking good man.  i'm sure you'll get many many miles out of that thing

on a side note, what are your comments on your water intercooler setup? i'd love to just have a thermometer gauge measuring the temperature drop etc.  no heat soak must be sweet  

[RabbitGTDguy]

I'm sure I will.

The AWIC setup is sweet. I'll be making some refinements this winter, but its done very well thus far. I'm still working on how I would like to measure intake temps for my own purposes...but I can tell from feel that things are really working well...

Joe

[RabbitGTDguy]

Well, the engine build continues...bottom end is almost complete. I'm wrestling with some turbo choices for both of my mTDI setups at the moment. One holset is on the way and another may be in the works We'll see

As far as an update. Well, thinking towards winter right now and trying to get things ready. Passat just went through inspection today with flying colors after basically rebuilding the rear end of the car in the last month with all new bearings, rotors, MKIV caliper upgrade (which is easy and can be done FAR cheaper than 200 bucks as most list...have another set to go on the MK1), new ebrake cables, mintex of course, etc. Good stuff...last inspection as a gasser def. though. I've even thought about doing the swap in the winter here as I do have back up transpo with my brother now living in the area.

So, a week or so ago I decided that the paint really need another good wax before it headed into winter. The paint on the car is quite faded and really needs to be resprayed...hopefully, in the spring here.  However, wax does clean it up for a little while and it looks nice. So...did that.
Also, a hailstorm this summer had crack one of my preferred "clear" Hella DE headlight housing.  I had a set of smoked housings that I had bought for spares after I got the car that had been damaged/repaired as well and didn't want to risk damaging the clears anymore...so the smokes had gone on. The original intention for the smoked units was to repair them, smooth them out and color match them to the car. Not sure of the look...I just kind of had left them alone all summer long.

Well...that changed. Got inspired, pull the covers, plastic weld a lot of sanding and paint later and here is the product.



I think I like the end product a lot more than I originally thought I might. It will be even better when they are truly completely matched to the color of he car itself. It makes the lights blend to the car alot more without them being a standout on there own.  I think the blending gets me the most. For many that don't know the b3, the hellas always REALLY stood out and made you question...huh? Now they just look like part of the car...but they flow. Don't know if there is a better way to say that but I think that is what I'm getting at Flow....
Needless to say. I think they will stay color matched for the respray in the spring.

Additionally, not wanting to throw on the winters quite yet, I trade the rims that I had on the car in the pictures above for a set of 4x100 BSI rims that my brother had. I was never a fan of the multi-lug setup of the other wheels and my brother has had a itch for the rims that I had.  I found this set for him a while back and we ended up trading. Think I like these better as well! They will be blasted, stripped and possibly polished this winter. If not, repainted def.





So, that is the update for now.

A new addition is coming to the family as well soon. Another VW of course. I am getting a Corrado shell (complete) within the monh. Another diesel target as well. A few years off....but it'll be  PD swap or a new CR swap Finish the Mk1 and have this as a driver first though. Hopefully, more motor build pictures to follow here this weekend of the b3's engine.

Still trying to find a complete set of black leather b3 doorcards if anyone has any around (or knows of any).

Joe

[oldskool rich]

that B3 is sick, ive always had love for these cars, after seeing what you did to ur mk1 i trust that this one will be equaly as impressive. i just dont know how you have the time, i spend every waking minit tinkering with my cars, yet i never seem to get anything done, certainly not as much as you, well done mate, keep us updated :wink:

[RabbitGTDguy]

Thanks...appreciate that. The b3 will be tuned more towards the best blend of power/performance and economy. However, it will be close to the motor of the mTDI Mk1 and is already slightly larger since this is using the 1st oversize TDI pistons. It also has the 4bt pump base, etc. The pump still has the 12mm head which I'd like to replace with a 11mm BOSCH unit *no China junk* but I haven't found one yet. I'd trade the 12mm unit. Otherwise, I may end up leaving the 12mm in there or going to a 10mm with larger nozzles. I think PP520's or 764's will be in its future. For now, I have Bosio Sprint 764's to run. I had toyed getting rid of it but I just don't think I can. I haven't had gremlins that the later models *especially VR's* seem to have had and I have gotten my initial investment in it back ten fold in cost savings, driving it, etc. the last few years. Going again, flawless through inspection yet again. After working out the shortcomings of the PO, it has been great and still is FAR less than what another new car would cost So. Keep them all. Soon, an all diesel fleet!

As for time. I don't seem to have alot of time either. Usually...a 1 day devotion a week or sporatic throughout the week. These changes were over the course of two days as detailing took forever so I felt comfortable with the paints winter protection. Busy busy...first year teacher...so I am whooped after school many times but now with some heat in the garage and colder weather approaching....it'll be more relaxing to work after school. I just try to do as much as possible when I do have the time to be productive.


Joe

[jtanguay]

I'm sure I will.

The AWIC setup is sweet. I'll be making some refinements this winter, but its done very well thus far. I'm still working on how I would like to measure intake temps for my own purposes...but I can tell from feel that things are really working well...

Joe

a sidenote about the AWIC, is that it would be an excellent system for the winter due to the colder temps, and being able to disable the cooling pump from over-cooling the intake air.  chalk up another win for the AWIC  

[RabbitGTDguy]

except for the fact that my AWIC doesn't see winter since its in the mk1, not the b3. The b3 may see a AWIC system though. Not sure. Debating that at the moment.

Joe