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Engine Specific Info and Questions => IDI Engine => Topic started by: holoffs on January 03, 2009, 04:26:30 pm
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I just picked upa 92 passat with a 2 litre gas motor and 5 speed. In my shop I have a 1.6 diesel and transaxle from an 87 jetta that I'm thinking of dropping in. Will this motor and trans drop in or will the diesel bolt up to the passat trans (as long as the final drive is good for highway cruising I'm fine with this) If not, can the hydraulic/cable clutch/linkage be converted to the older style mechanical/cable linkage on the 1.6v transaxle? What about drive axle diameters etc? Sorry about all the questions but I'm hoping to sort out the issues before starting to tear things apart.
Thanks for any info.
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Don't apologize for asking questions! that's a big part of this forum!
Speaking of which, sorry i can't answer them! :oops:
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Easiest will most likely be bolting the diesel to the passat trans. It should work just fine but you will need to find the correct flywheel/pressure plate combination.
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Easiest will most likely be bolting the diesel to the passat trans. It should work just fine but you will need to find the correct flywheel/pressure plate combination.
Right. You should stick with the Passat gearbox since otherways you would need different driveshafts too - and the Passat gearbox is much tougher than the Golf / Jetta one. As for the clutch assembly, you can use a TDI or G60 clutch for example.
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2,0 gasser Passat has already 228mm clutch.
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2,0 gasser Passat has already 228mm clutch.
And the flywheel will bolt right onto the 1.6 crank?
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2,0 gasser Passat has already 228mm clutch.
And the flywheel will bolt right onto the 1.6 crank?
Any 4cyl will bolt right on. 2,0 fw is same as G60.
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yup. keep the original tranny and clutch setup (obviously buy a new clutch kit) and bolt the diesel into the passat.
Be warned, you are seriously downgrading the power on that car and it will be extremely slow. Passats are heavy.
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On the other hand, it's extremely easy to make the TD produce more power than the stock gas engine..
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Easy maybe, cheap not really. It takes money to get a TD to produce more than 136hp.
i was assuming the OP was referring to an N/A diesel as it was not specified.
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And it will still get better fuel economy while doing it! :D
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16v's are high revers. Check the gear ratio out on it before deciding anything. Since you are under-powering the car, a higher revving transmission may work to your benefit to some extent.
You could convert the passat to the older style 020 transmission, but I don't think it's worth the hassle. Finding a good 02a diesel transmission is also an option.
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the passat has the 16v/tdi/g60 flywheel
the pressure plate has the same bolt pattern for both vr6 and g60 flywheels
4 cylinder and 6 cylinder friction disks have different part numbers
(http://i25.photobucket.com/albums/c85/diy_ak47/motor/clutch.jpg)
this is just an example and an information source I suggest to shop around for best price and to compare part numbers
the total cost from most vendors is about $150 for those 2 parts.
the final drive on the passat transmission is fine for freeway cruising
02a ayk = .837 5th x 3.684 ring pinion = 3.08:1 final drive
02a agc = .795 5th x 3.94 ring pinion = 3.13:1 final drive
find the code on the transmission on the flat spot on top of the transmission just left of the shift tower
be sure to remove the catalytic converter from the passat if you go diesel
the 16valve engine from your passat is desirable and rare you can sell it on vwvortex.com or craigslist.com to pay for the clutch
my opinion is one sided, I will never buy another gas car as long as I live.
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Voodoo is correct. Although, finding a diesel 02a might be something to keep an eye out for. Teh ratios are more desirable. But if its NA and you plan to drive it around town it should be fine. I dont think I could deal with the RPM limit that would be imposed if I put an NA diesel in my Passat. I guess it probably wouldnt matter too much as I dont think it would make it to 70MPH lol!
People will pay a decent price for a 2.0l 16v with all the wiring. the last one I sold went for $900.
Oh and dont buy stuff from MJM, they suck. :p
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Thanks for the info. I'll check the final drive on the Passat and also look into wheel/tire diameters and compare them to the trans/tire size combo in my 87 Jetta diesel. I will be using the car for a lot of highway driving and suspect a final drive over 3:00 will be too revy for what I want. would it be possible/realistic to change the final drive in the Passat trans to something in the 2:60 range?
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i dont think that would be possible. I have never heard of a final drive ratio of 2:60 on any o2a.
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You can search the web for 02A gear ratios.
The tallest available final drive ratios are about 3.1 IIRC.
BUT, if you'd use a diesel 02A, you would get pretty interesting ratios:
0.71 fifth gear and 3.1 final drive would come to 249 kmk/h at 5000 rpm and a cruise speed of 120 km/h at 2400 rpm....
The gasser ratios are also pretty long in Passats, just look at the tables and you know what I mean :)
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Also, some Passats have the infamous dual mass flywheel - which is fine - if you're not after any serious power.. If you are, just replace it with a solid G60 flywheel and you're good to go.
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I did some ratio research and comparison today. Here is what I found out but first a little background. I have an 86 2 door jetta non turbo diesel with the AGS trans which I found too buzzy on the highway (3.94 final drive and .75 5th gear equaling 2831 rpm at 110 kph.) I'm just finishing a trans swap to the ACN 5 speed (3.67 final drive and .75 5th gear which should be about 2637 rpm at 110kmh :D ). My Passat has the 3 CES trans which has a 3.68 final drive combined with a .837 5th gear equaling 2950 rpm at 110 kph :( ). The TDI Passats came with a 3.94 final drive and a .717 5th gear working out to 2706 rpm at 110 kph. :) . How about this. Could a TDI 5th gear set be swapped into my CES trans resulting in 2500 rpm at 110 kph? :D . Tire sizing for all the above examples are 195-60-14.
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Yes it could. But maybe easier to source a longer-ratio gearbox instead?
There are some versions of the 02A that have really long ratios. Something like 0.71 5th and 3.1 final...
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keep in mind that with super long ratios, that passat may never see 110kmh. 52hp just wont cut it.
to the guy from Finland, in North america, we never got any transverse Passats with dual mass flywheels and pretty sure Europe didnt either :p
A 3:94 final and a .71 should work out fairly well if the engine is still in good shape. Still dunno about the 110kmh though. That could take some time.
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The engine I have for the passat is a turbo diesel and my goal is to get it up to 100 hp so I think 110 km/h cruising is no problem. I can do 110 with my non-turbo Jetta (sans hills of course). The TDI passat trans would work but I'm not sure about availability. I didn't see the ultra low ratio 02a (.71/3.1) on the search I did. Can anyone give me a number or application for that trans so I know where and what to look for. Also, any ideas where I can source gears for these transmissions?
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I'll see if I can find the gear ratio chart again, later today.
As for your cruising speed goal - 100 hp should do fine. My ALH Skoda Octavia had 90 hp and the top speed was 182 km/h....
About the dual-mass flywheel - well, if that's really the case then it's all easier. Someone told me the 351 Passats have it, but if not, no clutch problems then!
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I didn't see the ultra low ratio 02a (.71/3.1) on the search I did. Can anyone give me a number or application for that trans so I know where and what to look for.
OK. The gearbox code ASD
1st: 3.300
2nd: 1.944
3rd: 1.308
4th: 1.09
5th 0.717
Final: 3.16
Those are pretty tall ratios already.