Just as the title says, this is for swapping the Mk3 AAA 2.8 VR6 engine and 02A transmission into the Mk1 cassis.
Im going to write this in the hope that it can become a sticky for everyone. Ill add bit and pieces over time, so keep checking back.
Ill do my best to cover all available options on how to do this based off of my experience and collective knowledge of the other members who have helped me along the way.
The information provided is here for everyone to use. Comments, suggestions and corrections to possible incorrect information are always welcome.
I plan on breaking this down in sections in no particular order, but will do my best not to go all over the place. :laugh:
RESOURCES
Here’s a list of all places that you will probably have to check out to get this project done.
NOTE: I will add/edit and links that need to be provided you PM me.
I have also provided links to my Dropbox with the full Mk3 and Mk1 Bentley manuals, so no more scourging the internet for them
1: (Electrical Diagrams)
http://www.a2resource.com
2: (SAI delete)
https://sites.google.com/site/stoyn...moving-the-sai-secondary-air-injection-system
3: (VR6 conversion kit)
http://shop.eurowise.com/category-s/278.htm
4: (Mk3 Bentley Manual)
https://www.dropbox.com/s/nk1jwtkpyqihqk1/MKIII Bentley Manual.pdf?dl=0
5: (Mk1 Bentley Manual)
https://www.dropbox.com/s/ivnvu5iif4vg15q/Mk1 Bently.pdf?dl=0
6: (Mk1 Parts Resources)
http://www.autohausaz.com/index.html
https://www.rockauto.com
7: (Cabriolet info)
http://www.cabby-info.com
NOTE: While this site is primarily focused around cabriolets, It has a LOT of good info that can be used on a standard Mk1
DONOR CAR
This writeup is talking about the Mk3 VW’s. While the Mk4 VR6 can be used in a Mk1, there are different procedures that have to be followed that I am not familiar with.
Here are a few notes to be taken…….
1: Find a car that hasn't been gutted yet. Its a lot easier to sell off what you don't need then to scavenge for what you do.
2: If you are doing this project on a budget, there are a few things that can be done to help keep some hard earned clams in the bank.
Use the stock radiator, some cutting will have to be done, but it fits well.
Use the stock exhaust manifold / down pipe. It will have to be cut short and at an angle to clear the steering rack, but works just fine.
3: Don't spend any money on aftermarket performance mods unless your 100% sure that it’s the route you want and can afford to go. By the way, that little car is going to be a little rocket ship.
4: Here is a list of everything you will want to pull off of your donor……
Engine
Transmission
Radiator
ECU
Full engine harness (take as much wiring as you can, you can strip off what you don't need later)
Cable shift box
Fuse box
All coolant lines
Oxygen (O2) sensors
Guage cluster (if you want to go that route, I will show how to get everything hooked up)
Guage cluster harness
This will get you going for now. There may be a stray nut or bolt you will have to get, but this covers 99.9% of what you will have to take.
MOTOR MOUNTS :heart:
As much as I condone making your own parts, Skip the headache and just go buy the Eurowise kit. http://eurowise.com/shop/index.php?main_page=product_info&cPath=1_841_853&products_id=11
You will be very happy that you did.
The guys at the shop are VERY helpful and are willing to answer any and or all questions about their kit that you may have.
WIRING AND STUFF :what:
This is the Mk3 fuse box showing only the harness point that are needed to make everything work including the speedo cluster.
I have blanked out everything that is not needed in an effort to make this simpler to read.
Here it the breakdown of whats on here.......
D Miscellaneous Equipment (GREEN)
D/08 Auto. Trans. Shift Lock Control Module, Interlock Relay, Malfunction Indicator Switch, E/2 (cluster power for A3) Main Fusebox Start/Run Power (Black)
E Instrument Wiring Harness (GREEN)
E/02 D/11 or D/8 (Start/Run Power for cluster, 1991+ Corrado, Passat, all other models), Immobilizer Module U2/1 (Black)
(NOTE) YOU WILL NEED TO JUMPER THESE TWO TERMINALS ABOVE TO GET YOUR MK3 GUAGE CLUSTER TO WORK!!!!!!!
G1 Engine Compartment/Management, Right Side (WHITE)
G1/03 ECU- Fuel Pump Relay Turn-On (gas), Engine Temp Sender (Pre-heat, diesel), thermoswitch for preheat (carb) Fuel Pump Relay Power (Red/Yellow) (gas engines),
G1/04 Ignition Coil Pin 15 (Digifant and CIS-E), Motronic ECU Pin 14 and coil power stage Pin 1(Motronic), Altitude Correction and Fuel Cut-Off Valves (diesel) Main Fusebox Start/Run Power (Black) (gas)
G1/05 Ground on Cylinder Head Ground (for gauges/warning lights) (Brown/White)
G1/08 Heated Oxygen Sensor Power Fuel Pump Relay Output, Fuse 18 (Red/White)
G1/09 MIL Lamp from ECU (TDI) Gauge Cluster MIL Light (Yellow/White)
G1/10 Digifant/Digijet ECU Power, Injector Power (1989 only), ISV Power (G60 only) Digifant ECU Relay Output (Black/Yellow)
G1/11 Vehicle Speed Sensor Gauge Cluster (White/Blue)
G1/12 Ignition Coil Pin 1 (all Mk2, most others '90 only), ECU tach signal (all 91+ except Mk2) Tachometer (Red/Black) (coil) or (Green/Black) (ECU)
G2 Engine Compartment/Management, Right Side (WHITE)
G2/01 Oil Temperature Sender Gauge Cluster (MFA) (Green/Black)
G2/03 Coolant Temperature Sending Unit Coolant Gauge (Yellow/Red)
G2/04 Knock Control Unit, Oxygen Control Unit, and Throttle Switches (CIS-E), automatic choke and overrun cutoff valve (carb), Heated O2 Sensor (Digijet), Fuel Pump After-Run Control Unit and Crankcase Ventilation Heater (G60) Main Fusebox Start/Run Power, Fuse 15 (White) (carb), (Black) (all others)
G2/05 MIL Light from Motronic ECU (Passat VR6) Glow Plug Relay Pin 9 (Yellow/White)
G2/06 - Fuel Pump Relay Pin 5 -
G2/08 Secondary Air Injection Pump Power, EVAP Canister Valve Power (VR6) Fuel Pump Relay Output (Red/Blue)
G2/09 VR6/ABA Motronic ECU (Fuel Pump Input) Fuel Pump Relay Input (Red)
G2/10 High Oil Pressure Switch Oil Pressure Warning Unit (Yellow)
G2/11 Low Oil Pressure Switch Oil Pressure Warning Unit (Blue/Black)
G2/12 - (no pin) -
H1 Steering Column Wiring Harness (RED)
H1/04 Ignition Switch Start/Run Power Main Fusebox Start/Run Power (Black)
H1/07 Ignition Switch Key-in Power for Seatbelt Relay, Automatic Shoulder Belt Control Module, Radio Seatbelt Warning Relay Pin 5 (Brown/Red)
M Fuel Tank Wiring Harness (BLACK)
M/01 Fuel Pumps Ground Main Fusebox Ground (Brown)
M/02 Fuel Pumps Power Fuel Pump Relay Output, Fuse 18 (Red/Yellow)
MISC.
Y/03 Battery Positive Main Fusebox Battery Power (RED)
-Z2 Battery Ground Main Fusebox Ground (BROWN)
....and what the harness should have on it at the end......
USER SUBMISSION :wave:
This will be a spot dedicated to user who submit good useful info. So please, PM me or submit to the thread. The more detailed on how to do, gather, perform, finish and find the info you submit, the better for all.
Im going to write this in the hope that it can become a sticky for everyone. Ill add bit and pieces over time, so keep checking back.
Ill do my best to cover all available options on how to do this based off of my experience and collective knowledge of the other members who have helped me along the way.
The information provided is here for everyone to use. Comments, suggestions and corrections to possible incorrect information are always welcome.
I plan on breaking this down in sections in no particular order, but will do my best not to go all over the place. :laugh:
RESOURCES
Here’s a list of all places that you will probably have to check out to get this project done.
NOTE: I will add/edit and links that need to be provided you PM me.
I have also provided links to my Dropbox with the full Mk3 and Mk1 Bentley manuals, so no more scourging the internet for them
1: (Electrical Diagrams)
http://www.a2resource.com
2: (SAI delete)
https://sites.google.com/site/stoyn...moving-the-sai-secondary-air-injection-system
3: (VR6 conversion kit)
http://shop.eurowise.com/category-s/278.htm
4: (Mk3 Bentley Manual)
https://www.dropbox.com/s/nk1jwtkpyqihqk1/MKIII Bentley Manual.pdf?dl=0
5: (Mk1 Bentley Manual)
https://www.dropbox.com/s/ivnvu5iif4vg15q/Mk1 Bently.pdf?dl=0
6: (Mk1 Parts Resources)
http://www.autohausaz.com/index.html
https://www.rockauto.com
7: (Cabriolet info)
http://www.cabby-info.com
NOTE: While this site is primarily focused around cabriolets, It has a LOT of good info that can be used on a standard Mk1
DONOR CAR
This writeup is talking about the Mk3 VW’s. While the Mk4 VR6 can be used in a Mk1, there are different procedures that have to be followed that I am not familiar with.
Here are a few notes to be taken…….
1: Find a car that hasn't been gutted yet. Its a lot easier to sell off what you don't need then to scavenge for what you do.
2: If you are doing this project on a budget, there are a few things that can be done to help keep some hard earned clams in the bank.
Use the stock radiator, some cutting will have to be done, but it fits well.
Use the stock exhaust manifold / down pipe. It will have to be cut short and at an angle to clear the steering rack, but works just fine.
3: Don't spend any money on aftermarket performance mods unless your 100% sure that it’s the route you want and can afford to go. By the way, that little car is going to be a little rocket ship.
4: Here is a list of everything you will want to pull off of your donor……
Engine
Transmission
Radiator
ECU
Full engine harness (take as much wiring as you can, you can strip off what you don't need later)
Cable shift box
Fuse box
All coolant lines
Oxygen (O2) sensors
Guage cluster (if you want to go that route, I will show how to get everything hooked up)
Guage cluster harness
This will get you going for now. There may be a stray nut or bolt you will have to get, but this covers 99.9% of what you will have to take.
MOTOR MOUNTS :heart:
As much as I condone making your own parts, Skip the headache and just go buy the Eurowise kit. http://eurowise.com/shop/index.php?main_page=product_info&cPath=1_841_853&products_id=11
You will be very happy that you did.
The guys at the shop are VERY helpful and are willing to answer any and or all questions about their kit that you may have.
WIRING AND STUFF :what:
This is the Mk3 fuse box showing only the harness point that are needed to make everything work including the speedo cluster.
I have blanked out everything that is not needed in an effort to make this simpler to read.
Here it the breakdown of whats on here.......
D Miscellaneous Equipment (GREEN)
D/08 Auto. Trans. Shift Lock Control Module, Interlock Relay, Malfunction Indicator Switch, E/2 (cluster power for A3) Main Fusebox Start/Run Power (Black)
E Instrument Wiring Harness (GREEN)
E/02 D/11 or D/8 (Start/Run Power for cluster, 1991+ Corrado, Passat, all other models), Immobilizer Module U2/1 (Black)
(NOTE) YOU WILL NEED TO JUMPER THESE TWO TERMINALS ABOVE TO GET YOUR MK3 GUAGE CLUSTER TO WORK!!!!!!!
G1 Engine Compartment/Management, Right Side (WHITE)
G1/03 ECU- Fuel Pump Relay Turn-On (gas), Engine Temp Sender (Pre-heat, diesel), thermoswitch for preheat (carb) Fuel Pump Relay Power (Red/Yellow) (gas engines),
G1/04 Ignition Coil Pin 15 (Digifant and CIS-E), Motronic ECU Pin 14 and coil power stage Pin 1(Motronic), Altitude Correction and Fuel Cut-Off Valves (diesel) Main Fusebox Start/Run Power (Black) (gas)
G1/05 Ground on Cylinder Head Ground (for gauges/warning lights) (Brown/White)
G1/08 Heated Oxygen Sensor Power Fuel Pump Relay Output, Fuse 18 (Red/White)
G1/09 MIL Lamp from ECU (TDI) Gauge Cluster MIL Light (Yellow/White)
G1/10 Digifant/Digijet ECU Power, Injector Power (1989 only), ISV Power (G60 only) Digifant ECU Relay Output (Black/Yellow)
G1/11 Vehicle Speed Sensor Gauge Cluster (White/Blue)
G1/12 Ignition Coil Pin 1 (all Mk2, most others '90 only), ECU tach signal (all 91+ except Mk2) Tachometer (Red/Black) (coil) or (Green/Black) (ECU)
G2 Engine Compartment/Management, Right Side (WHITE)
G2/01 Oil Temperature Sender Gauge Cluster (MFA) (Green/Black)
G2/03 Coolant Temperature Sending Unit Coolant Gauge (Yellow/Red)
G2/04 Knock Control Unit, Oxygen Control Unit, and Throttle Switches (CIS-E), automatic choke and overrun cutoff valve (carb), Heated O2 Sensor (Digijet), Fuel Pump After-Run Control Unit and Crankcase Ventilation Heater (G60) Main Fusebox Start/Run Power, Fuse 15 (White) (carb), (Black) (all others)
G2/05 MIL Light from Motronic ECU (Passat VR6) Glow Plug Relay Pin 9 (Yellow/White)
G2/06 - Fuel Pump Relay Pin 5 -
G2/08 Secondary Air Injection Pump Power, EVAP Canister Valve Power (VR6) Fuel Pump Relay Output (Red/Blue)
G2/09 VR6/ABA Motronic ECU (Fuel Pump Input) Fuel Pump Relay Input (Red)
G2/10 High Oil Pressure Switch Oil Pressure Warning Unit (Yellow)
G2/11 Low Oil Pressure Switch Oil Pressure Warning Unit (Blue/Black)
G2/12 - (no pin) -
H1 Steering Column Wiring Harness (RED)
H1/04 Ignition Switch Start/Run Power Main Fusebox Start/Run Power (Black)
H1/07 Ignition Switch Key-in Power for Seatbelt Relay, Automatic Shoulder Belt Control Module, Radio Seatbelt Warning Relay Pin 5 (Brown/Red)
M Fuel Tank Wiring Harness (BLACK)
M/01 Fuel Pumps Ground Main Fusebox Ground (Brown)
M/02 Fuel Pumps Power Fuel Pump Relay Output, Fuse 18 (Red/Yellow)
MISC.
Y/03 Battery Positive Main Fusebox Battery Power (RED)
-Z2 Battery Ground Main Fusebox Ground (BROWN)
....and what the harness should have on it at the end......
USER SUBMISSION :wave:
This will be a spot dedicated to user who submit good useful info. So please, PM me or submit to the thread. The more detailed on how to do, gather, perform, finish and find the info you submit, the better for all.