It's been a slow progress building this thing, finding time between work and university.
Subframe was fitted from a Audi 80 B4, difference is that b4 subframe has an additional transmission mount and lacks engine mounts (engine mounts to the unibody on B4, B5...)
First i mounted the B5 transmission with the B4 transmission mounts, had to massage transmission tunnel with a sledge hammer. Then I combined B4 and b5 shift linkages to fit my B2. A lot of cutting and welding later I could shift the transmission.
Axle shafts from the b5 don't fit onto b2 because they are longer 2-3cm than stock, had to find B4 TDI axles, swapped outer cv joints.
Replaced the transmission oil and fitted a new B4 slave cylinder.
Then came the engine. Resealed everything, new oil pan, new glowplugs, water pump, timing belt and oil...
Installed the engine into the car, bolted it up to the transmission. Used 1.6 front mount to position it correctly. Then fabricated and welded subframe engine mount brackets. After that used B5 front engine mount that also serves as intercooling piping. A lot of cutting and welding later i had all mounts side and front.
Used B4 pedals that seemed to fit without a problem but of course they are a close fit but new mounts needed to be made. After that i drilled the firewall for the clutch slave cylinder. Hooked everything up and bleed the clutch. It works.
A little while ago i found a 5 cylinder Passat in a scrapyard that someone swapped a 1.6 into but left everything else in it. Took all the ac parts from the inside as well as the brake fluid bottle with the drain for the clutch.
Mounted the Ac evaporator (firewall cutting and welding, had to braze b5 ac line connectors since someone broke off the original ones), mounted the fresh air fan plastic housing with the vacuum actuator for the ac, also the 3 speed fan switch was replaced with the 4 speed one.
Did inside electrics for the fog lights and all other accessories i installed so that they all run through CE1.
Found a b3 speedo hoping it would work with b5 transmission speed sender, and it works. Now I need to install that in to the original mk2 speedo housing. Why the b3/b4 speedo, because they are individual, you can take the speedo out without tach for example and it would work, as in mk2.
Regarding the engine, IP was timed to 1.45mm, 1.6 td intake ported to fit 1.9tdi, turbo actuator welded a bong to it so i could use a boost line on the lower half with a manual boost controller. Did the engine wiring. Hoped i could use 1.6 head water outlet but bad luck, different angle for mounting. So i had to use 1.9tdi water bracket. It has a 4 wire temp sender. Hooked it up so it could work with my 1 wire gauge. I have cut off the clutch fan from the water pump bracket, so different belt routing and length had to be used 1650 5pk. Brand new alternator 140a, w terminal soldered and hooked up.
IP was fine but yesterday it started to rev hang, i dont know why. Maybe stuck delivery valve or something. You start it up and its okay, as soon as you rev it it hangs at 2k rpm and stays there until you overload the engine and then it would go back to normal idle. Probably rust from sitting for too long idk. After unscrewing the fuel screw it doesnt hang permanently on 2k but slow to come down. Was fine a few days ago. Have to solve that.
Yeah also welded a part of the 1.6 IP fuel lever so i could retain the "no smoke at startup" lever thingy on the lr pump. Also remade the 1.6 throttle cable bracket to fit lr pump.
Still have to do intercooler, ac lines and condenser and speedo. Radiator fans are still a problem but i'm thinking I could make mk4 golf fans fit so they push air, with that setup i can install the ac condenser. Intercooler is going to go on the outside (bumper cutting..).
Probably forgetting to mention a lot of things, but give me a brake its been a couple of months now since i've started this build.
Topic: mTDI Passat b2 swap, your help is much appreciated (Read 8621 times)
