VAG 1.9 TDi into a RWD transit

[oldskooler]

awesome progress luke. ill be watching this thread like a hawk!!!

[Luke]

thanks mate - always good to see it done 1st make little improvements for when you do it i copied your idea for the gearbox crossmember but made it so its welded to the chassis and unbolts - if the engine has to come out after its finished it will need to be dropped below on both crossmemebers (because the box is so big) - doing it this will make it easier to locate



i might have an exhaust mount on here too and a coupling behind it - to make it easy to undo for engine removal

ive actually finished welding up the engine mounts but i cant get the pics off my phone - i will post them once i do.

[Luke]

managed to get the pics of my phone

this was modifying the front mk1 crossmember as the 1.9 sump is lower

1st marked it out took it off and cut it, then tacked in 2 angled box sections



then bolted it up back on the van - clamped it together and marked it out



then cut the piece out tacked it in in situ



then removed it ready for fully welding

[Luke]

this picture shows the finished (not painted yet) crossmember - the circular disks were cut out of plate with a hole saw - they seat the passat engine mount rubbers, they also utilise the hole in the crossmember so they can be unbolted from underneith - bit of luck really

the engine mounts were made in the usual way - plates cut and bolted to the block then tacked to the mounts - removed and welded up the o/s one is an odd shape as it has to go round the starter motor. these need painting too but i want to check it all bolts up before painting them



tomorrows job is to bolt it all up so i have the engine sat on the mounts

[BROWNYS V6]

nice bit of metal fab

[karl]

i agree nice work luke

[Luke]

thanks guys got it fitted and sat on the mounts now - i had to trim a bit back of each one to get them to fit but they are in now

pics to follow

the inlet manifold fouls on the servo does anyone know if all inlet manifolds are interchangeable just looking on ebay there are loads with the inlet pointing the other way that would do the trick

there isnt much room for the rad - it wont be able to go all the way across the front of the engine but i should have enough cooling area - if not i will have to fit twin rads - but i'd rather do that than chop out the bulkhead

[martynx]

Some people use 2.0 SDI inlet manifolds on 1.9's. Fitting may be the same across all euro 3/4 1.9/2.0 Tdi /PD/SDI. Not sure though.
I have an '01 non PD Leon if you need an inlet pic?

[Luke]

i think they will swap like you say - ive found this one on ebay for £15 might just take a risk

http://www.ebay.co.uk/itm/VW-TOURAN-GOL ... 463bc40be3

[martynx]

i think they will swap like you say - ive found this one on ebay for £15 might just take a risk

http://www.ebay.co.uk/itm/VW-TOURAN-GOL ... 463bc40be3

Can't go wrong at 15 quid

[Luke]

o/s mount - you have to remove the turbo support strut to get the starter out but ive seen worse on mass production cars



n/s mount - you can see from the other pic how ive had to trim off the top support - still plenty strong enough

[Luke]

and the engine sat on all the mounts



you can see the inlet fouling on the servo - obviously plenty of space above the engine

there looks a lot of space in front for the rad but once the panels on its very tight

[Luke]

i took the inlet manifold off and it looks the same so i bought it - fingers crossed

decided to fit a Lotus Elan M100 radiator - bit expensive but it will fit all the way across the front of the engine - only downside is i will have to relocate the alternator lower down so i'll need to make a bracket for it

the 2 pipes running across the front of the engine are i believe the fuel cooler radiator - i'm hoping i dont have to fit this as i have a metal tank and i think its because the passat has a plastic tank and the returning fuel can get hot

[Luke]

ive taken the gearbox back off and fitted the adapter plate - all lines up perfect

but the crafter starter wont mesh to the passat flywheel means i'll have to buy a crafter DMF flywheel and clutch

also looking at the gearbox sensors on the passat i think all they are is reversing lights and speedo - there is no sensors on the crafter box - for the speedo i will use a gps one until i get the original one sorted and i dont think i need reversing lights for MOT but they might be on the stick?

it would have been easier to do this with an MT75 as the speedo drive and reverse lights would be there

[Marty.H]

No reverse lights needed for MOT