86 MK2 Golf TDI Conversion
SCRATCH AREA FOR CONVERSION
File:MK2-Golf-TheSamba-ad.pdf - This was the orginal TheSamba AD, it was already up for 7months! I was amazed it was still up. I pointed out what was wrong with it and offered $1000, and they took it!
MK2 Golf Price Cost List of conversion
I recently picked up a 1986 VW MK2 Golf diesel 1.6na which I plan to upgrade to a TDI.
Stock 1.6na 86' Golf engine bay photos for reference
Stock 1.9 TDI 98' Jetta engine bay photos for reference
Contents
External References
tdiclub - List of TDI Conversions
Required B4 Parts
There are some B4 parts that need to be obtained:
- B4 Pedal Assembly - P/N 3A1-721-111B
- B4 Hydraulic Clutch / Brake Booster Bracket P/N 3A1-614-123B
My Build References
My Youtube Playlist for CE2 Harnesses
Other Build References
FYI / Helpful Hints
- MK3 TDI trans has a taller final drive to go with the tiny tires of the older cars
- Stock MK3 1.9 TDI subframe is same stance as the MK2, just stronger. If you want a wider stance, get the MK3 VR6 subframe. A passat subframe does not fit. Passat front cross bar fits in MK2, but the MK3 front cross bar does not.
- B4 Passat TDI, MK3 Jetta/Golf TDI; the entire pedal assembly (100% bolt in) and it's 02A transmission - if you can get whole car.
Donor MK3
If you get lucky as I did and get a whole MK3 Jetta TDI, some things can move over and some things won't or have no need. However, gut EVERYTHING other than the interior panels and set it aside. In case you DO need it.
02a Transaxle
The 02a MK3 TDI (CTN) transaxle is perfect gear ratios for the smaller tires of the MK2 platform.
In the same respect the O2a shift tower is an improvement over the 02m shift tower. However, people have also adapted the later 02j shift-towers into their MK2s. I happen to have the 02a shift-tower with the transaxle I got, so upgrading to that this round.
Axle Flanges
From the Vortex:
"MK2s also use two different inner flange diameters - 90mm and 100mm. I *think* all mk3 are 100mm, so you have to be careful which inboard end you're using. You can also swap driveshaft flanges on the trans itself apparently. "
For the swap to the MK3 TDI CTN transaxle, use the MK3 axles.
KFrame
The MK3 4cyl subframe aka K-Frame is identical to the MK2 just stronger.
However, the front cross member isn't suitable for mounting to the MK2; the B4 Passat though fits and from what I read there is a differnce from the TDI variants -TDI Club Photo comparison for reference
Front Suspension
The whole front suspension is an MK2 upgrade.
EXCEPT for one major grey area . . .
The MK3 4cyl control arms are roughly 1" longer than the stock MK2 ones, and the VR6 control-arms are even longer. What does this mean? It increases your stance width, or as common called 'wide stance' if you change it from a MK2 setup. If you want to lower it, a "Wide Stance" setup handles better, but for the shitty roads I travel, I'll keep it stock MK2 stance.
That means, I'll be setting the MK3 control-arms aside as tie-rods and using the ones from the MK2.
Because, MK2 control arms are getting hard to obtain, people opt to just use the slightly larger MK3 4cyl ones. I will however, use what's stock on the MK2 till they get tatered up or can't be obtained any longer.
CE2 Harness
This is good to grab to use some of it on the MK2 and the rest to remake the CE2 harness for the MK2.
Or if lucky grab a newer MK2 (90-92) CE2 harness assembly and reinstall into your older MK2.
A/C Components
Much of this will move over or will be modified down the road.
Radiator & Fan Assembly
This will work on the MK2 with either a B3/B4 front crossmember and some upper radiator mount fabrication. Because in todays day and age a B3/B4 parts are more and more scarice I'll be installing the following Fabless Manufacturing gear.
Harness Research
Aquired Parts
Harnesses
- MK2 1992 16V Golf CE2 harness
- MK2 1992 Jetta EcoDiesel Engine bay harnesses
- MK2 GTD Cluster and MK3 TDI Cluster obtained, will rock the MK2 till I get tired of it and put the MK3 one in, unless there's a main reason to just go to MK3.
Harness References
The 1999.5 ECU is physically the same size as a 2000-2003 ECU - the main difference is you can not program the 1999.5 ECU over the OBD port; instead, you will need to install sockets on the boards where the ICs used to be soldered into place and then get new ICs sent every time you want to change the software.
That system works, but if I was starting this project and gathering parts, it would be so much better to start with a 2000 to 2003 EDC15 ECU ALH. The AHU ECU is 2x the size of an ALH. Your MK2 cluster will work just fine. Modifying the 02A/J VSS to accept the cable to the speedometer is simple. Making the tachometer work is just the Digital to Analog converter.
CE1 to CE2
USA MK2 Golf's were not CE1 or CE2 they were a bastard. So you need all the CE2 shit:
- heater/AC control panel.
-Any CE1 or CE2 Mk2 (with round fan switch)
Fuse box bracket: 191937581B / 191937589
Reference
JAX @ VW Vortex on steering columns and stalks
So, the 86' VW Golf is a USA Elect (General Motors related) interface that can be adapted to work with newer engines. However, the better method is to update from CE1 to CE2 which allows for future engine upgrades easier. It's a more standardized and easier to work with interface.
WHITE - Engine - GOT IT
YELLOW - FRONT END - NEED
YELLOW / AC - MK2
Steering Column & Stalks
So, there's a bit of confusion with what steering column and stalks to use. JAX on (TDIClub & VW Vortex) said this:
"I swapped my 86 to ce2. I kept the original column. The decision comes down to where you want your hazard button to be. I opted for the mk3 wiper and turn signal switches with the hazard button on top. I cut away the column upper plastic to fit the button and removed the old hazard switch harness.
I used the mk2 ignition housing and switched to the ce2 switch. Small spline mk2 steering wheel. No need to swap anything else"
There was also this mention on vwvortex
"However the collar section of the U-joint between the column and rack is identical on both cars. Go to a junk yard and get the mk3 U-joint and uninstall the mk2 u-joint from your cars column. You'll be able to see the similarity. The collar is attached to the u-joint via a crushed spline - with a die grinder and a press you'll be able to free the collars and move the mk3 to the mk2. Two quick spot welds will refixture it and you can now run the mk3 steering rack with a mk2 steering column."
Cluster Upgrade
Two common methods
- Install later MK2 tacho gasser clusters
- Install a MK3 TDI cluster
- Super Rare ; CE2 Turbo Diesel with tacho
Years
So, I got an 1991 GTD cluster, so I need wiring for that year.
Subframe (K-Frame)
The MK3 TDI (with AHU in USA) such as a 1998 Jetta TDI, fits directly on the MK2.
The biggest reason to upgrade here, is to get the modern motor mounts for the TDI and not the MK2 Golf.
You can also swap the entire suspension + subframe over to a MK2; this only applies to MK3 4cyl engines the VR6 is a different beast.
Front Cross Member
Passat B3 and B4 will work, or one from Fabless, but the MK3 will not work if you use a MK3 subframe and rad fans.
ALH Motor Mounts
DarkSide MK2 ALH VNT motort mount
From the Interwebs on TDIClub
""The passenger side Mk3 motor mount will bolt to the Mk4 ALH block, the Mk3 front motor mount 'sandwiches the engine and transmission @ the starter and will also work without issue on the mkiv block.'"
Then for the transmission mount. My guess would be to use the Mk3 transmission. That should mount the engine solidly. "
A/C Update
The 86' I got is a base model with A/C, so not even power-steering. The donor MK3 TDI 98 Jetta I have has A/C installed.
References
Methods
There's a few different upgrade methods one can go which depends on the type of dash you plan to have.
MK2 Dash
The a/c section of the airbox is a straight fit, just swap the MK2 air distribution part onto it (the bit with the heater matrix in) fit a new heater matrix and repair the flaps if required. you'll need mk2 a/c glovebox and dash shelf, or just chop your old ones down till they fit. then its a case of adapt the wiring, no worse than the engine conversion really. hardest bit is the a/c controls, either find factory mk2 a/c slider panel and graft it to mk3 wiring, or add your own switches for a/c on and recirculation grafting them ontyo your loom.
you can get mk2 dash switches for them, these were fitted in mk2s which had a dealer a/c conversion fitted rather than factory fit. the VW vortex is a great source for those. or you could use fog/screen switches suitably adapted, or other car switches glued into a mk2 dash blank
You can have any combination of mk2/3/4 flap and fan housings, the fit between them is the same
It's been discovered the MK4 air-con box fits better in the MK2 than the MK3 one which can still fit in.
MK3 Dash
Brake Booster / Clutch Master Bracket
References
Part Vendors
If unable to find a B4 or Corrado booster bracket, S&P makes one that works without ABS: S&P
Synopsis
You need to install the booster bracket that allows a hydraulic clutch then drill the hole for that clutch master to install into.
Methods
The pedal cluster from a B4 Passat, the original mk2 brake cylinder and booster, a 357612209A brake booster bracket from a non ABS Corrado, and a 357721401 clutch master cylinder.
You need to match the brake booster, pedal cluster, and clutch master
Rear ebrake
MK2 was updated with a GTI rear axle and disc brakes, but the ebrake is weak:
"" Quote, originally posted by 16v po boy » swapped rear discs from a 87 jetta onto a 91 gti. now.... late gti ebrake cables are too long. early gti cables are way too long. any suggestions???? wtf? any soultions. i have about 4-5 inches too much here. to my knowledge only 2 size cables exist. early ( 85-87) and late (88-92) late being the shortest wehich i have and are too long. ?????
There are also two types of e-brake lever, an early one and a late one, maybe that has something to do with it. "
Steering Rack
Steering Rack Discussion
Interior Insulation
Old insulation is crap lil under 1/2", best to use Butyl automotive sound deadener and use closed cell foam in a roll; the closed cell foam likely quarter inch thick assuming the Butyl is about a quarter inch thick too.
