Upgrade to 1.9TDi

[Hungry_Horse_1955]

Right, as the transfer box on my Country is kaput (see other posts), I have decided to install a 1.9TDi engine & gearbox.

I was initially going to buy the parts to do this but after looking on mobile.de it looks as if I can buy a complete Mk3 Golf TDi Syncro for under EUR1000, complete with ABS and A/C! Only trouble is I’ll have to take a day or two to ‘pop’ over and pick one up.

Anyway, logistics aside, what parts are straight swaps, apart from the usual engine, gearbox, transfer box, rear diff/VC unit?

Does the propshaft fit?
Is the loom a plug and play job?
Is the ABS system the same as the Mk2 one?
Is the A/C compatible with a Mk2 one (if I can find the cabin parts)?
Does anyone know what rear brakes the Mk3 Syncro has?

I will probably have many more questions, but I first need to obtain a donor vehicle. Before I go the whole hog and practice my vast knowledge of German (zilch) does anyone have a Mk3 TDi Syncro lounging in there back yard that they don’t want? Chris, would your local scrap yard have something similar lying around? []

[Chris S]

Does the propshaft fit? Probably but it is a 2 piece rather than a 3 piece prop

Is the loom a plug and play job? Its VW so if its not plug N play then it shouldn’t be far short

Is the ABS system the same as the Mk2 one? No, the 93 model has mk4 ABS & the 94 on has the mk 20 system, but it should work in the Golf 2 as the wheel sensors & rotors are the same

Is the A/C compatible with a Mk2 one (if I can find the cabin parts)? Dont know for sure, but it should work

Does anyone know what rear brakes the Mk3 Syncro has? Drums the same as the G2 Syncro, however the Golf 3 rear swing arms(Triangles) do not have the mounting lugs for the caliper carriers!

Chris, would your local scrap yard have something similar lying around? Sorry no

[Hungry_Horse_1955]

Looks like a trip to Germany to visit my Brother is in the offing!

[Chris S]

You can also call in here as well if you like!

[Hungry_Horse_1955]

Sounds like that could be a good idea!

[Cokkeli]

Hungry Horse please make a detailed project diary or something like that, i would be very interested to follow it. hmmmmm…. TDi…. ggrrlll…. hmmmm… Black smoke…. mmmmmm….. grl glrglrl…

[re2]

i too have been thinking along the 1.9 tdi route for a while. Luckily by transfer box is ok. Wouldnt it be easier to get a transfer box and then just swap the engine. I even contemplated the 1.6td as its quite a tunable engine but its a wee thing and i bet the 1.9 is more tourqey

[Hungry_Horse_1955]

I did think about buying the parts, but invariably something is missing and I’ll end up spending money buying the little bits I forgot! I’d also have to change the gearbox. At least if I bought a complete car, everything should be there [], plus a few extras like the ABS and A/C [^]

With regard to ‘Black Smoke’, I was also thinking of fitting an LPG system to it. If you set it up for around 10% LPG it erradicates the black smoke as the mixture burns a lot better. It also improves the efficiency of the engine giving increased MPG or more omphh, depending on how you use your right foot! Search ‘Diesel LPG Conversion’ in Google!

[Chris S]

Member jimtdi over here in the Netherlands is also doing a Diesel conversion on his 1986 Golf 2 Syncro.

[Chris S]

quote:

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Originally posted by re2

i too have been thinking along the 1.9 tdi route for a while. Luckily by transfer box is ok. Wouldnt it be easier to get a transfer box and then just swap the engine. I even contemplated the 1.6td as its quite a tunable engine but its a wee thing and i bet the 1.9 is more tourqey

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The only problem with using the original gearbox is that the final drive ratio is 20 to 25% to short, then you get higher revs at lower speeds even in 5th gear,
So you need to swap the diff over for the 2wd Diesel diff, which as its the first thing fitted into the gearbox casing makes it very expensive to change,
I know how long it takes cos I have rebuilt Syncro gearboxes a few times.

btw Apart from the differential the 020 Syncro box already has the Diesel gearing!

[re2]

ok, so all ill need is a standard Golf Syncro gearbox and the original diesel diff or will the standard syncro gearbox do?
ta chris

[Chris S]

Sorry Dave, somehow I missed your last post.

the std Syncro box already has the Diesel ratios but you would be better off buying the complete mk 3 Syncro box

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