I figured that there are a few posts out there regarding the use of the turbodiesel exhaust manifold and turbo on a gas VW...but none really answered my questions...so I tried it for myself and here is a rough "how-to" for the swap
Sorry there arent any pics, my digital camera is a piece of crap and the pics it takes probably would'nt help at all.
Here are the parts that can be used from a turbodiesel VW:
-oil feed and return lines
Here are the key points to the swap:
-You need to flip the exhaust manifold upside-down (boltheads that attach the turbo to the manifold should be facing up) to get it to fit on a non-crossflow head, otherwise the intake manifold wont fit.
-You need to grind down the exhaust manifold to allow the intake manifold to line up again...If you take the turbodiesel manifold and the stock intake manifold and try to fit them togeather, it'll be really obvious which parts need to be ground down
-If you dont know how to "clock" a turbo...now is the time to find out!
-In order to make the upside-down turbo work you have to do some adjusting. the exhaust housing and compressor housing are both held in place by only a few bolts, if you remove them (all you really need to do is loosten them) you will be able to adjust the orientation of both housings.
-With the turbo upside-down the oil feed and drain lines are upside-down too , which is a bad thing (especially if you want to use the turbodiesel oil lines). Here's how I solved that problem: I took it all apart and bolted the exhaust housing to the manifold (which was bolted onto the head), then I CAREFULLY slid the middle section (with the oil fittings, and NO compressor housing) into the exhaust housing and I turned it until the oil feed hole was pointing up and the drain hole was pointing down. THEN I slid the compressor housing on with the outlet pointing towards the firewall (the only way I could see it fitting good enough to run IC piping). Then I marked the housings with some small scratch marks so when I took all of them back off I would be able to align them correctly (VERY important step!). There really is no way to be able to put the bolts back in with the turbo on the car....
-So, now that the turbo is all oriented correctly, you may notice a HUGE problem... the shift linkage runs right into the compressor housing It's a easy fix though, just take off the L shaped piece that it runs into and beat it with a hammer until it is flat enough to clear the inlet of the compressor side
This is as far as I got today, Ill keep ya updated
[Modified by EuroVeeDub, 5:40 PM 10-13-2002]