B3000 TDI swap

[Whitbread]

nice so the drive turbo is controlled by the external WG?

Yes, I removed the wastegate in the K03 and welded a plug in it's place. The external gate sits on the egr port on a 96-98 tdi manifold and dumps into the hot pipe to bypass the HP turbine and control peak boost. The hx30 has it's own internal gate to control the LP stage boost.

 

[Whitbread]

After almost 6 hours of welding, all done!

 

[Whitbread]

Beefy support bracket


Bolted in for good! Oil drain lines all done and tight, hot pipe heat wrapped, and oil feed lines halfway made.

 

[Motohead1]

That looks great. I may have to copy this turbo setup on mine eventually if nothing else just to lower hwy cruise egts. I imagine your cruise EGTs loaded will be much cooler.

 

[planeflyer21]

That looks great. I may have to copy this turbo setup on mine eventually if nothing else just to lower hwy cruise egts. I imagine your cruise EGTs loaded will be much cooler.

I was thinking along these same lines.

Whitbread, have you thought about selling plans for your setup?

 

[Whitbread]

That looks great. I may have to copy this turbo setup on mine eventually if nothing else just to lower hwy cruise egts. I imagine your cruise EGTs loaded will be much cooler.

I'll definitely let you know how it works! I have another compound tdi and that setup works very well, it's just set up for 300+hp, so it's not as responsive on the bottom end.

Whitbread, have you thought about selling plans for your setup?

Plans for what exactly? I'm just tossing a bunch of random parts together haha.

 

[planeflyer21]

Piping for the K3 and intercooler setup, which exhaust manifold, etc.

300+hp is more than I'm seeking out. 283 lb ft of torque would be really nice though.

 

[Whitbread]

Piping for the K3 and intercooler setup, which exhaust manifold, etc.

300+hp is more than I'm seeking out. 283 lb ft of torque would be really nice though.

All the info is here in my thread, or just ask away .


Got all the coolant bypass lines done, intake manifold, rest of the tubes made over the weekend, and vw ecu fit in the ford ecu box. Had to mill 3/16" off each side of the ecu case, but it fits now. Time to build the exhaust tomorrow!

 

[Curious Hound]

wow. That fits nicely, even with the OEM air conditioning box in place.

 

[planeflyer21]

wow. That fits nicely, even with the OEM air conditioning box in place.

Agreed. Look at all that room in there!

 

[Die.Fledermaus]

I notice that the BRM doesn't offer a power steering pump, or a V-belt drive...I assume yours is similar. What is the plan (if any) to avoid armstrong based steering?

Is your donor equipped with a dual pump (tandem high pressure and vacuum source ?pump deuce specific?) that can run the ford power brake booster.

 

[Whitbread]

I notice that the BRM doesn't offer a power steering pump, or a V-belt drive...I assume yours is similar. What is the plan (if any) to avoid armstrong based steering?

Is your donor equipped with a dual pump (tandem high pressure and vacuum source ?pump deuce specific?) that can run the ford power brake booster.

The BRM uses an electric rack so that's why there's no power steering pump. I'm using a BHW (b5.5 passat) long block with a BEW (mk4 jetta/golf/beetle) accessory setup which does have a power steering pump. I'm fairly certain a BEW accessory setup will bolt onto a BRM block. I don't have a block to test fit it on though.



Started wiring in the dash. Check suspension light will now be the glow plug light thanks to greengeeker's findings on that, tagged on a wire to ford vss signal to feed it to vw ecu for cruise control, and pulled the tach signal wire out of the ford harness since a dakota digital box will now run tach off can bus data stream from vw ecu.


Got the dp all done, 3" fit perfectly! Going to feel a little bad covering this with heat wrap.




Midpipe tucked up like a glove

 

[Whitbread]

Dana 4.10 gears went in


Finished up the tailpipe

 

[planeflyer21]

A bit off the engine subject but what brand gears did you select for your 4.10s?

 

[Whitbread]

A bit off the engine subject but what brand gears did you select for your 4.10s?

They're Dana gears, bought from rock auto for $125.