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914World.com _ 914World Garage _ 1974 1.8 Turbo conversion
Posted by: pgollender May 5 2019, 09:05 AM
Finally beginning the 1974 1.8 T conversion. Bought the donor car over 1 year ago and began stripping it out last week. The goal is to modernize the cockpit and cabin a bit to enjoy things like Cruise control and A/C and intermittent wipers and boast power a <bit>with a KO4 turbo. The donor car was a 1999 Passat 1.8T longitudinal 5 speed.
I was inspired by both Mike Bellis and Andrew Dallens conversions. I don’t have big aspirations for enormous HP gains. I’ll be satisfied at 165-175Hp.
I plan on using the original Passat gearbox and custom fab the axles and cable shifters.
Ideally I’d like to design the cooling system and intercooler to stay in the original engine bay, but we shall see.
Attached thumbnail(s)
Posted by: pgollender May 5 2019, 09:26 AM
Passat wiring harness, 100% intact. Bitch to remove. Many unneeded connections, but at least I can pick and choose. Instrumentation panel will be Passat.
Posted by: pgollender May 5 2019, 09:33 AM
Recipient vehicle 1974
Posted by: Andyrew May 5 2019, 12:46 PM
Watching 
Let me know if you need any help.
165-175hp is stock turbo at about 12-13psi. Very conservative setup. You could make about 225 with the setup maxed out.
Posted by: jb6000 May 5 2019, 02:12 PM
Going to be a nice car.
Posted by: whitetwinturbo May 5 2019, 07:51 PM
..............that's a challenging mash up 
Posted by: get off my lawn May 6 2019, 03:54 PM
Passat wiring harness, 100% intact. Bitch to remove. Many unneeded connections, but at least I can pick and choose. Instrumentation panel will be Passat.
That looks like a bad acid trip.
A really bad one.
Posted by: pgollender May 6 2019, 08:44 PM
Watching
Let me know if you need any help.
165-175hp is stock turbo at about 12-13psi. Very conservative setup. You could make about 225 with the setup maxed out.
Thanks Andrew, I'm sure I will need to stand on the shoulders of those who have gone before me.
Posted by: pgollender May 6 2019, 08:46 PM
That looks like a bad ]
[/quote]
acid trip.
A really bad one.
[/quote]
Only worse acid trip is one in which you haplessly cut all the wires to make the job "easier".
Posted by: 914-d May 7 2019, 12:58 PM
If you don't have it already, you are going to need vagcom or vcds as it is called now. Computer program for working on vag products.
Where in nor cal are you. I have the program ane might be able to help
Posted by: Andyrew May 7 2019, 01:08 PM
He can also buy the Chinese $20 cable/program. I havent had any issues with that.
Posted by: Chris H. May 7 2019, 01:18 PM
Only worse acid trip is one in which you haplessly cut all the wires to make the job "easier".
Yeah you really have to pull the whole harness just to be sure you don't accidentally cut something you need. Quite a BITCH to get out of the car but worth it in the end.
Looks like a clean donor engine/other parts! Check out Andyrew's thread as well as @MikeBellis Probably more I just don't remember.
Posted by: Chris H. May 7 2019, 01:19 PM
Double Post!
Posted by: pgollender May 8 2019, 02:53 AM
Power plant is out. Time for a cleaning and respec/rebuild
The passat tranny has a low profile. 
1999 Passat wagon DBW decommissioned.
Posted by: pgollender May 9 2019, 12:53 AM
If you don't have it already, you are going to need vagcom or vcds as it is called now. Computer program for working on vag products.
Where in nor cal are you. I have the program and might be able to help
Roseville area. Thanks, I do have access to bonafide vagcom system !
Posted by: falcor75 May 9 2019, 01:57 AM
Nice project, I built a Mk1 Scirocco with the 1.8T and it turned out plenty fast with just the stock 180 hp engine (traction was an issue into third gear) The Scirocco is a little lighter than the 914 but its only about 100 kg difference and rear wheel drive will make it awsome. If you want to keep the stock look I'd look at a small watercooled intercooler, much more efficient and easier to find room for.
Posted by: pgollender May 11 2019, 07:54 PM
Yellow car on it's way to new garage for body work and rust repair
Posted by: pgollender Dec 20 2022, 08:47 PM
Car on the spit. 1.8T on the stand
Posted by: pgollender Dec 20 2022, 08:50 PM
box-o-engine parts
Posted by: pgollender Dec 20 2022, 08:54 PM
will clean up and rebuild forged internals, JE pistons, longer stroke
Posted by: pgollender Dec 20 2022, 08:58 PM
Original brain box from Passat donor = Audi. Will keep for start-up but replace before APR chip and tune
Posted by: pgollender Dec 20 2022, 09:05 PM
Original K03 turbo. Will replace with slightly larger K04, better boost controller and air-to-water intercooler.
Posted by: pgollender Dec 20 2022, 09:21 PM
Front engine view: Will delete viscous fan, water pump, power steering pump (three cluster on the lower right). Relocate the AC (on the lower left) to where the PS pump is now to allow for cable shifter clearance and cleaner front. I plan on using electric water pump with controller to account for longer coolant push to front mounted radiator.
Posted by: pgollender Jan 15 2023, 10:10 PM
The moment you realize that it took you 4 weekends just to get everything apart and now you have to start to deplete your bank account.
Last icky creepy step:
I may call her "Spidey"
Posted by: pgollender Jan 29 2023, 05:52 PM
Weekend progress: Got the heads back from the machine shop. I still haven’t found any local machine shop that wants to bore the Passat block. Seems like they all closed shop. 
Posted by: pgollender Jan 29 2023, 05:59 PM
Old suspension is off. Getting ready to send out to get powder coated. Headed over to Shingle Springs to pick up my new coil overs from Ground Control. New Bilsteins, bushings and bearings arriving later this week. 
Posted by: pgollender Feb 7 2023, 08:16 PM
First upgrades arrived today. Big shout out to Jay at Ground Control in Shingle Springs, California. I am literally starting at the ground up.
Posted by: erwan914 Feb 21 2023, 04:19 AM
First upgrades arrived today. Big shout out to Jay at Ground Control in Shingle Springs, California. I am literally starting at the ground up.
good project
spirings LBS for rear ?
Posted by: pgollender Feb 21 2023, 10:38 AM
First upgrades arrived today. Big shout out to Jay at Ground Control in Shingle Springs, California. I am literally starting at the ground up.
good project
spirings LBS for rear ?
I went pretty stiff, 175#, but the front will be stiff too with 19mm torsion bars, Tarrett anti-sway bar, and adjustable Koni's. All new bushings everywhere and rebuilt steering rack. Once it's on the ground and running, I have a 150# spring option as well if i need to adjust the ride response. Trailing arms about ready to go. Waiting on the bearings.
Posted by: pgollender Feb 27 2023, 12:07 AM
Obtained accessory carrier and peripherals from 2002 Jetta and test mounted on the block to see if it would fit. This switches the AC pump (and everything else) to the left side of the block and gives a cleaner shot and more room for the cable shifters, turbo and the exhaust on the right side. First pic is the original configuration and the second is the new relocated peripherals. 
Posted by: Mayne Feb 27 2023, 06:37 AM
Looking good! I’m guessing by the forged internals, etc, that stock power is out the window. Sounds like a good plan of action!
Posted by: pgollender May 5 2024, 11:21 AM
Progress report: life and health issues causing 914 conversion delays. Back to the grind. Spent last few weekends de-rusting, repainting and replacing new seals and bearings for all suspension parts. 
Posted by: technicalninja May 5 2024, 12:06 PM
Really cool project!
The 5 valve chambers look kick ass!
I'm an AC guy...
How does the serpentine belt route?
You really need 180 degrees of belt contact on the AC compressor. Most factory serp set-ups have more.
The original drivetrain has an alternator with a standard pully. The converted picture has an alternator with a "de-coupler" pully. For high rpm use I'd want to throw the decoupler in the trash.
You might be able to merely swap the pullies.
Good description: http://www.metroplexalternator.com/pulleys.html
What he doesn't mention is the faster this pup is spun the more likely it is to fail.
Lose one while driving and you'll swear "the engine is coming apart".
Worse noises than a "spoon in a garbage disposer".
Neat project!
Nice suspension!
Posted by: pgollender May 5 2024, 09:12 PM
Really cool project!
The 5 valve chambers look kick ass!
I'm an AC guy...
How does the serpentine belt route?
You really need 180 degrees of belt contact on the AC compressor. Most factory serp set-ups have more.
The original drivetrain has an alternator with a standard pully. The converted picture has an alternator with a "de-coupler" pully. For high rpm use I'd want to throw the decoupler in the trash.
You might be able to merely swap the pullies.
Good description: http://www.metroplexalternator.com/pulleys.html
What he doesn't mention is the faster this pup is spun the more likely it is to fail.
Lose one while driving and you'll swear "the engine is coming apart".
Worse noises than a "spoon in a garbage disposer".
Neat project!
Nice suspension!
Tnanks, the serp belt routing details still need to be worked out. I have begun stressing over them. I did not know that decouplers can fail at high rpm's. I'm certain, there will be a few times pushing the limit.
Posted by: pgollender May 5 2024, 09:15 PM
Steering assembly mostly done.
Posted by: pgollender May 7 2024, 04:51 PM
Engine block back from Engine ReNu in Modesto, bored out to 83.0mm, so total displacement with the stroker crank is 2098cm, therefore will need 2.1T badge when completed and on the road. Rotating assembly all balanced plus have the IE dynamic fluid harmonic balancer as a final step in balancing. Gapped the rings today but stopped short of putting the connecting rods on because of the piston ring c-clips being a total bitch.
Took a dash out of a wrecked 2007 Cayman and it's amazing how well it fits between the A-pillars. It's a little deeper than the stock 914 dash. Just playing with the dash ideas... the Passat dash also fits in the same space.
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