Vent windows, GTI spoiler and Suspension Strut Top Cover

The vent windows were sand blasted and painted, the glued glasses were removed to put in bolted ones that are more secure.

Fuel tank with lift pump

To remove the fuel tank i had to unbolt the rear axle, the rest is pretty easy.

Only the first PD cars didn't have a lift pump so i wanted to use one on my car.

The easyest way is to use an external pump but i wanted to use a lift pump in my tank but needed a swirl pot just like on cars with PD engine.
External swirl pot was not something i wanted to do.

The pd swirl pot is too big to fit throught the mk1 hole in the car and i didn't want to cut it so i had to find a smaller one.

I bought a mk1 cabrio pump but it was too complicated to make an internal swirl pot that would fit with the PD lift pump adapted there and fit trought the mk1 tank hole.

I bought a mk2 GTI lift pump and made those adaptors so it would fit on the metal mk1 tank, it would be more easy to make the swirl pot but still not a peace of cake.

Finally i found the perfect fit for what i wanted to do. It is a peugeot 106 / citroen saxo lift pump with swirl pot, 2/3 the size of the PD unit so a little bigger than the mk2 lift pump.

So i opened up the metal fuel tank to see the internal swirl pot and stuff

Here you can see the different sizes of the mk1, mk2/mk3, peugueot/citroen and mk4

Welded and grinded

Painted and placed under the car

Just need to connect the fue lines and i can close it

02M 6 gears shifter

Just a little plate to hold it in place.
The cables go next to the exhaust.

MK1 PDTDI first start

PDTDI Wiring

Iwill keep the mk2/mk3 fusebox but will adapt the mk4 engine wiring to it.

 

MK4 shortened driveshaft / drive axle

Bigger should be stronger so this is an upgrade from mk3 axle to mk4.

The wheel hub has the same bearing but bigger spline so i bought a mk4 hub and drilled 3 holes to have both 4x100 ans 5x100, and a 2mm (i guess) spacer is needed before pressing on the bearing.

Shortened the small one 30mm

Shortened the big one 75mm

Painting

All done