Okay, just got out of a night class! Time to finish up and bring you guys up to date. I go to Drexel University for Mechanical Engineering. I had an internship at Volvo Powertrain in Hagerstown, MD last summer (the big turbo diesel Volvo and Mack Trucks). I was pretty much alone down there and bored so one of the mechanics was nice enough to let me use his garage for the entire summer! Another coworker sold me this for $1100:
Which quickly became this:
I parted it out and definitely made more than my original investment back, even keeping the 1.8T AEB 20v motor.
Then came time to tear into the Rabbit.
Original JH solid lifter 8v 1.8L CIS motor:
After some Purple Power and a thorough power washing:
primer:
and paint:
It turned out better than I expected. It was a quick job because I was on a strict time limit. I started in July and had to be done by September to move back home!
In order to fit the front motor mount, I had to switch to a mk3 oil filter housing, which points straight down instead of to the side like the original Passat housing. Also, the TDI mk3 already had an oil feed line to the turbo from the housing, so it was a perfect candidate.
No Power steering needed in this 1800lb car! and A/C is a luxury that my bay has no room for. Therefore, some brackets needed to be modified:
I also only wanted to run one Serpentine belt and get rid of all v-belts. The vr6 is the only water pump pulley that runs a serp belt from a vw, so vr6 h2O pump pulley it was!
Lucky for me, Volkswagen used basically the same block for most of their 4 cylinder engines from the late 70's all the way up to the late 90's. My early 1.8T AEB block was essentially the same as my 1.8 JH block. therefore, although the Passat didn't use the same mounts as the rabbit, the holes in the block were still there. They just need some rethreading
The motor sat Longitudinal in the passt, but I needed it to sit transverse, so I needed to make some other custom fabrications as well. Timing belt cover:
with rabbit motor mount installed. this motor mount is from an HD kit. You can also see taht I used a 16v tensioner, since the rabbit mount took up the space from the passat's auto-tensioner:
I then took a string and put it around my setup to measure for how long a serp belt I needed:
I also wanted to get rid of all that PCV sh*t. who wants oil in their intake? My intercooler was filled with it. thank you 034 motorsports for an adapter
Next up was the oil pan. Because I went from the motor sitting longitudinal to going transverse, the motor tilts back farther, and the oil sits differently in the pan, so I had to switch to a transverse oil pan and pickup tube setup as well. What's also sweet is they make a really nice baffle/gasket combo for a mk3 pan. I traded the catalytic converter off the passat for an entire mk3 ABA motor from a mk3 GTI. that's where all these mk3 parts are coming from
Also got my machine shop to weld in a bung for the turbo oil return line:
