in the middle of a swap, any help appreciated Options

[smrtkd69]

me and a buddy are swapping my motor into his car. i have a 91 awd automatic tsi and he has a 90 awd 5 speed tsi. both motors are finally out, but after removing the clutch assemblies there are some differences on the shaft exiting the block, like a half an inch. i haven't taken a real hard look at what its all about yet, but should have i expected this? if so is there any recommendations out there to finishing up the job? this is our first swap and i am buddy buddy with the haynes manual but there seems to be no info about this in there. any help would be appreciated. thx guys.

[xian 1g]

a good place to look would be vfaqs.com

if you go to 1000 already answered questions and scroll down the left side you will see information about swaps.

if he has a late model 91 his transfer case will be a 23 spline, and your 90 will be a 22 spline. this is a problem.

another thing you might run into is that the td04 turbo (auto-provided your auto is a turbo) has smaller coolant lines than the td05 turbo (manual)

here are few other differences:
For 1Gs, there are several differences between manual and auto cars of the same year, aside from (duh) the transmission.

Auto 1G cars have
- smaller turbochargers
- smaller injectors (390cc)
- a 'power/economy' switch located next to the shift lever
- ECUs designed for the smaller injectors
- cams designed to produce more low-end torque [1G only]

Manual 1G cars have:
- bigger turbochargers
- larger injectors (450cc)
- a nifty little coin holder next to the shift lever, a fave place to put electronic widgets of one sort or another.
- ECUs designed for the larger injectors
- ECUs designed to produce less low-end torque [1G only]


there is a nice write up about doing your swap there for fwd's but i didn't see one for awd's.

I am not an authority on this subject, and am just using the vfaq's. the vfaq's has given me outdated information before such as the cuase for crank walking. do not take my information to heart, I just hope this helps.

[JMoushon]

The auto cars have a plug in the end of the crank that has to be removed as well.

[smrtkd69]

thx guys but we figured it out. lol. it was the stupid sleeve/plug in the end of the crank on the auto that was throwing us off. it was 7 in the morn and we had pulled an all nighter so we just weren't looking at anything right. but its all together now. what a success!!! thx again

[xian 1g]

congrats