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1.9 TDI swap iekš mk2

Posted: 09.02.2015, 22:47
by Saspraude_mk2
Sveiki biedri! Varbūt varat izpalīdzēt ar dažādiem linkiem, kur ir noderīga informācija par TDI swapu?

Tas tiešām noderētu, jo nav īsti brīvā laika pavadīt stundām ložņajot pa googli.

Re: 1.9 TDI swap iekš mk2

Posted: 09.02.2015, 22:54
by Mika
"If I were doing a MK2 TDI this is the list of parts that I would plan on but then again there are many different ways to accomplish the swap:

CE2 Mk2 (late 1989-1992)
B4 or Mk3 TDI for engine and drivetrain parts
B4 Pedal Cluster
B4 Engine wiring matches the mk2's holes better then the mk3 but they can both work. Careful with mixing and matching the ECUs, wiring harnesses, injectors and injection pumps. The glowplug circuits have different wiring. make certain you have the correct glowplug wiring that matches the ECU if if want the glowplugs to work properly without CELs. I also think that the 1Z engines have a lower popping pressure on the injectors so mixing and matching the ECUs could cause some issues here to.
Mk3/b4 TDI instrument cluster wiring as well as OBD2 diagnostic port. the B4 and Mk3 have minor differences in the cluster wiring. My recommendation would be to use the cluster wiring that is ment for the cluster. On my AHU Corrado I made my cluster's wiring harness from a bunch of spare aba and g60 cluster harnesses. What a PITA. On a corrado use a Passat TDI cluster.
I like the OBD2 diagnostic port mounting bracket that is used on the mk4s for mounting this plug wherever you want. I put my 1st one up under the dash. my 2nd one is under the shift boot Both used the mk4 mounting bracket. I like it under the shift boot more.
Mk3 or SLC K-frame (You can use a mk2 frame but it does not allow for the better motor mounts that the VR6 and TDI use) Passat will NOT work at ALL
Passat/SLC front crossmember (must use a Vr6 style motor mount) Mk3 will NOT work at ALL
ABA 2L or TDI 1.9L rear motor mount bracket
b4/mk3 tdi front motor mount bracket. The B4 ABA 2L 5spd front motor mount bracket is the same.
Any mk3/rado/b3/b4 02A transmission bracket
TDI motor mounts (Vr6 mounts will work but I'm uncertain of the vibration & longevity qualities)
In my opinion the mk2 diesel fuel tank is the best bolt in tank. The mk3 Jetta tdi tank will also fit. You can also use your mk2 gas tank but you will need to modify your spout and regulate the fuel pump's pressure.
For the instrument Cluster I will leave you with no perfect option. B4 or Mk3 TDI instrument cluster based on which dash you intend to use. The Mk3 fits the mk2 dash better. The B4 fits the corrado dash perfectly. Some have swapped MK3 and Corrado dashes into Mk2s neither of which is a simple task and there dozens of minor issues on all options. You could also try and build a hybrid mk2 cluster as show here:http://forums.tdiclub.com/showthread.php?t=303682
Use a mk2 TD airbox or a cone filter. Some have modified the 8V's airbox. I attempted this before getting my TD's airbox and wasn't satisfied with the aesthetic results.
Intercooler and pipes: This is something that depends on your car and which options you decide to keep.I used a G60 intercooler on my corrado. Big Bumper or Small, a/c or deleted, Hood scoop or OEM looking. I personally hate having a bunch of hose connections as each connection is just another opportunity for a boost leak. Sure you can mix match pipes and hoses to avoid custom metal pipes but my feeling is that its worth every penny to go custom. Some people have been able to use PVC and Copper from Home Depot. I like the Copper pipe idea and used it on a friends AEB Mk2 swap for a couple of water hoses. It was very easy to work with when compared to steel. Here is a thread with some MK2 intercooler ideas for those with small bumpers: http://forums.tdiclub.com/showthread.php?t=314080
Radiator just use a mk2 item. You can use a corrado but there is no need.
use the mk2 a/c wiring or adapt to the mk3/b4 setup (I used the Rado setup on mine which is the same as the Mk2's). I did use a SPAL fan with the factory fan shroud because it freed up some engine bay space and made the swap look much cleaner.
fuel lines: this can be done in a number of ways. I think I used gas lines my 1st tdi rado and mk3 tdi lines on my 2nd.
tdi fuel filter assembly
mk3/rado shift cables. Passat cables are a little longer then Mk3/rado cables and are thus not the best fit but they can be used.
mk3 tdi or mk3 2L Power steering High pressure line. I think the Passat one is too long.
mk2 axles are fine
mk2 control arms, spindles & brakes are fine but the mk3/b4 spindles and brakes allow you to upgrade to 11" brakes easily. The Mk3 and B4 control arms are longer then the Mk2. You could also swap in a 5 lug setup but this is a number of additional parts which has been covered numerous times on the vortex and other forums. Here is a quick stab at finding a thread about the parts required (if you find a better one let me know and I'll update this link): http://forums.vwvortex.com/showthread.php?3633102
mk2 PS rack is fine or you can use the mk3 part but remember that the tie-rods are different lengths because the mk3 control arms are longer.
mk2 swaybar is fine or you can use the mk3 tdi parts. The G60 Corrado's swaybar interfered with the cat's support bracket so I used the mk3 TDI swaybar.
Use the TDI donor's downpipe and Cat (if you don't upgrade or delete)
Rest of the exhaust can be whatever you want. Mine have use a mishmash of gasser mufflers and over the axle pipes.
fuel sender can be whatever you need for each fuel tank...mk3 tdi fuel tank is best with the mk3 tdi fuel sender. A Mk2 gasser fuel tank should use the mk2 gas fuel pump and sender. A mk2 diesel tank should use the mk2 diesel fuel sender. Sure you could swap things around but KISS (something most will say I don't follow very often). On my corrado I have tried the mk3 tdi fuel tank and it doesn't fit very well as the spout is too close to the door. I used a corrado tank with an enlarged nozzle opening. I don't know how a mk2 tank will fit in a corrado.
ECU Mounting? On my Corrados I had to make custom mounts as the ecu did not mount the same as the donor cars.
Battery Cables: I like the mk3 cables much more then the mk2 ones.
for a/c there are at least two routes
use the mk2 evaporator in the dash and have a custom line from the evaporator to the compressor created and then a custom line from the the compressor to the condensor
Use the mk3 evaporator and then use an SLC a/c line from the condensor to the evaporator. Use a mk3 TDI or ABA 2L or slc a/c line to the compressor from the evaporator. Have the compressor to the condenser line modified with the mk2 unit and tdi donor. My cost was $75 per a/c line for mods."

Re: 1.9 TDI swap iekš mk2

Posted: 10.02.2015, 08:39
by Marisio
Saspraude_mk2 wrote:Sveiki biedri! Varbūt varat izpalīdzēt ar dažādiem linkiem, kur ir noderīga informācija par TDI swapu?

Tas tiešām noderētu, jo nav īsti brīvā laika pavadīt stundām ložņajot pa googli.
Sāc pareizi domāt, ja liksi tdi, tad būšu priecīgs, ka pakāsu klientu :) labā nozīmē :thumbs:

Re: 1.9 TDI swap iekš mk2

Posted: 10.02.2015, 11:13
by Saspraude_mk2
Paldies Mika! :thumbs:
Marisio wrote:Sāc pareizi domāt, ja liksi tdi, tad būšu priecīgs, ka pakāsu klientu :) labā nozīmē :thumbs:
:thumbs: