1984 Jetta , TDI WE MUST! (1.9 AHU M-TDI)

[8v-of-fury]

Yeah I need the clutch to be stock, so it will be the weak part of the power transfer.. so that if something needs to give, the clutch will slip.. as opposed to breaking something. I have done a search on the vortex, and it would seem the pressure plates albeit a different part number share every bit of the same pieces. They are completely identical.

That saves me some money then, I can just order a 210mm 8v clutch kit. Here is a good question, will the same 210mm flywheel fit in the 4 speeds? I know general rule of thumb is all 020's will fit the three sizes of 020 clutches.. but you never hear the 4 speeds mentioned. I am using the 4 speed because it is low mileage, and the best geared trans i have for this TDI. It will be able to handle the big jumps between the gears of the 4A 4 speed.

[8v-of-fury]

what about pushrods? Are they 4 and 5 speed specific?

[CRSMP5]

yes pushrod is different.. one shorter..

pressure plate... 190/200 is same... 210 different..

flywheel... 210 is 210... 190 is 190... 200 will fit both 200 and 190... the machined part the disk touches is different diameter so a 200 will not work in a 190... but a 190 wil work in a 200..

[8v-of-fury]

I know the disks and all that, i was referring to will the 210 fw fit in the 4 speed 020's. lol. I will just be using a full on 210mm 8v clutch kit. No messing around lol. Shucks on the pushrod.

[R.O.R-2.0]

as far as I know there is no difference between the 8v and 16 PP other than maybe clamp force and the pins. I was told that the mexican pp are 2 pin and others are 1 pin... I was also told the MK3 are 1 pin and the rest are 2 pin. Just make sure that you know which pin you have and you will be fine. Also, the clutch must be the small spline IIRC it is 13/16" not 7/8" as the larger was the 16v spline. You will be fine. I have a clutchnet setup just like you are asking for, but not for sale.

if you have a mexi flywheel, it has 1 pin.. anything else has 2.

8v and 16v flywheels are the same.. the plate is the difference. the 16v plate has ALOT more clamping force.

i had a 210mm ABA clutch setup once, and i could slip it a tiny bit. thru the 16v plate in there, and no more slip..

in the near future, im going to be changing my clutch from a stock rabbit 200mm unit, to a 210mm mk2 clutch w/ 16v pressure plate..

my PP is off a used junk yard engine. it still had the original machining marks on it after i cleaned it up, so i dressed it with emery cloth, and used it.. worked perfect!

my 200mm unit is starting to slip on hard boost pulls and launches..

[8v-of-fury]

New parts are here!

210mm clutch kit -$140



Cast impeller Bosch Waterpump -$25



Some trans seals -$10






Going back to the spin on filter -$8



New motor mount -$8



I've also started the tear down of the TDI pump. Everything is the same inside, except for the throttle which is an interesting setup. Anyway it looks like everything will swap over very easily in to my 1.6 pump with no issue. I should be able to get that all done up and everything the day i pull my motor.. Hmm better yet, I think I will pull the pump off my motor a few days prior to the scheduled motor pulling and get the pump all built up and back on the TDI and running pre-swap.

[Powered by Spearco]

Um, the motor mount looks a lot like the trans mount insert. Could be wrong though.

Also, FYI, if you didn't know, you can use the water pump gasket from a 2.0L gas water pump  that is metal with rubber. I use them every time instead of the paper one. Makes a better seal too.

[8v-of-fury]

Um, the motor mount looks a lot like the trans mount insert. Could be wrong though.

It is a trans mount.. lol (its one of the four of what I call motor mounts lol)

Also, FYI, if you didn't know, you can use the water pump gasket from a 2.0L gas water pump  that is metal with rubber. I use them every time instead of the paper one. Makes a better seal too.

Didn't know that, thank-you very much for the insight. Will be picking one up.

Thanks for looking.

[CRSMP5]

fel-pro makes one ~$11... i also only use the metal/rubber one.. if i do not order one i pick up at zone... else it german brand.. but all honesty.. either works... ive taken apart both styles/brands on factory engines.. aka one golden with black ribbed rubber (german).. other silver with grey rubber (fel-pro).. not seen one fail.. and seen both as oe...

[8v-of-fury]

3.67 ACN BABY. Paid $60. Set up for mk1 use, However I am torn as to whether I will install the .71 5th gear i purchased?? or just remain with the .75 that is in the trans?? It will only drop the revs like 250 anyway right? I got the entire 5th gear from an FN for $30 For the trans I have a full clutch kit, pushrod, all the seals (mainshaft, pushrod, flange and axle), couple of throwout bearings for free , and I will be running synthetic trans fluid.




Now my question to you on this flywheel is.. Would Jesus Run It? However, if you are not biblical, would you run it? lol.




Still need to scribe TDC mark in to it, and remove the TDI's transmission and clutch assembly. Change out the water pump, and mount the VR6 water pump pulley. Then figure out what length belt I am going to need as I have deleted the A/C and power steering.

From then it is literally a matter of getting my car down to the shop, and tear the motor out so I can get the pump off of it and get to work building my m-tdi pump

[RadoTD]

new RPM = old RPM * .71 / .75
3000*.71/.75=2840

And that flywheel looks good to me! Scuff it up with some 120grit if it's smooth and throw it in!

[catlin_cava]

is this not done yet? and it better be at

MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!! MVOC!!

[8v-of-fury]

So yeah only 160rpm drop.. not too too worth it I don't think. Scuffin I will do.

CATLIN, FRGI!

[theman53]

Sell it to the guy going for the land speed record. How long have you been at this??? Still would have liked your wiring harness and such, oh well.

[8v-of-fury]

I have had this motor since.. September 2010.. Lmao. I am sorry I had to sell those electronics, was getting screwed by the government, and needed cash. I sold it all for a fair penny.

Swapping a TDI in to your daily driving 84 is no simple feat. It didnt get done right away because originally I wanted to do the whole shebang.. and if it werent my daily.. I would have..

Woulda swapped the whole car over to CE2 and used the entire 98 wiring harness. Kept the 02A cable shifted and hydraulic clutched. Kept it fully electronic, used the mk3 cluster.. blah blah.

OH WELL! THIS IS STILL GONNA BE FRIGGING AWESOME. I see no reason why 110-115hp is not reachable with a fully turned up 1.6TD pump and the K03 giving its all at 18psi.