Crossflow manifold to a Mk4 2.0 manifold on MK2!!!

[Blue92mk2]

Ok I have a 95 crossflow motor in my mk2 right now.....i just purchased the upper intake manifold from a Mk4 2.0 motor to swap it onto mine...the lower one will come shortly....anyways i heard it can be done with some modifying and whatnot....i didnt know if anyone knew the "how to" so i can get an idea how to relocate the throttle body and intake and such...please give me any insight that u might have....thanx

[JFryauff]

This all I could find, maybe it will help, since you are running a '95 crossflow.

All of this is in regards to OBD1
Parts:

MK4 Upper Intake Manifold
MK4 Lower Intake Manifold
MK4 Valve Cover
MK4 PCV Assembly
MK4 Oil Cap
MK3/4 Valve Cover Gasket
MK3/4 Manifold Gasket
MK3/4 Upper Manifold Gasket
MK3 Grommet for IAC Valve on Manifold
MK3 Elbow for IAC Valve on Manifold
(12) MK3 Injector O-Rings
5' of 3/4" Rad Hose
3' of 3/8" Rad Hose
6" of 1 1/8" Rad hose OR A Breather Filter that fits the MK4 PCV Assembly
1 1/2" copper coupling
1/8"x3/4" aluminum stock (home depot)
1/2"OD 3/8"ID Aluminum dowel (home depot
2.75" Flex Joints
2.75" Pipe 4"
(2) Plugs for Breather Lines
Assortment of hose clamps
Bolt to plug EGR
JB Weld
12 Pack

*** SAVE ALL PARTS YOU REMOVE - Most will be reused, otheres will be
slightly modified.

Pre-Game:

On the MK4 upper manifold you will notice a boss located on the passanger
side of the manifold...stick something in there thats hard and whack it
out with a hammer. Install the grommet and elbow in this new location. I
am unsure of the thread size for the IAT Sensor. Remove this from
the MK3 manifold, and you will need to drill/tap the MK4 manifold. The
best location for this was determined to be on the back of the manifold on
a thick area just below a vac connection.

- First things first, and I think this is kind of obvious. You need to
strip down your current setup so you're just staring at your MK3 Valve
Cover and nothing else.

- Unbolt and remove EGR System. You can plug the EGR with a bolt (Unsure
of the size). I personally JB Welded a bolt into the fitting on the
exhaust manifold.

- Disconnect the Block Breather Pipe.

- Swap the Valve Covers for the new MK4 design.

- Unclip the injectors and remove all the O-rings and discard. On the
head side of the injectors you will notice a little yellow band flapping
around, cut that off. Replace the original O-rings with the new ones, put
use two O-Rings on the Head-side of the Injector where you clipped the
Yellow Ring.

- Install the lower manifold and injectors watching to make sure you
connect them to the proper connectors.

- Install the MK3 throttle body onto the MK4 manifold upside down, remove
all parts on the throttle body that aren't needed (that dampener thing for
instance). The MK3 manifold has a nipple on it for the Evap connection.
This can be plugged off with what you find suitable, it is not used.

- Install the MK4 Upper Manifold

- Install the brackets you fabricated earlier (see photos)

- Trace the brake booster line from where it plugged into the old
manifold to the check valve. This line can be clipped and removed.
Install the 3/8" hose and route it to the vac connection on the back of
the manifold.

- Trim down the old evap line to the appropriate length and install it
onto the vac line on the passanger side of the manifold.

- Bolt the IAC Valve onto the "tab" on the passanger side of the
manifold. I was able to bolt it from the underside through the manifold.

- Reuse the original pre-shaped tubing, the elbow and the "Z" shaped
piece can be used to run from the elbow on the manifold to the port on the
side of the IAC Valve. Use the 1/2" Copper coupling to connect the two
hose pieces.

- Take the plastic tube that went into the intake boot and ran to the
IAC valve and trim it just before it makes the first bend. Plug one end
into the intake boot and connect let the other end dangle.

- Use a flex joint to attach a 4" extension onto the end of the throttle
body. Attach the 4" extension onto this flex joint.

- Plug the hole on the intake tube where the breather original fed.
This can be done with anything applicabe. Attach the intake boot to the
4" extension.

- Run a rad hose from the IAC hard line that you cut to the other end of
the IAC Valve.

- Attach the MAF and filter to the end of the boot. You can get
creative here and route some type of CAI, or pipe this however you want.

- Plug the breather hole on the block directly above/on the filter
housing. Use an O-Ring and an appropriate size plug with the factory
O-Ring.

- Attach the 1 1/8" rad hose to the MK4 breather and let vent to
atmosphere...OR attach a breather filter right to the PCV.

The following sensors will need to be extended:

Mass Airflow Sensor (MAF)
Idle Air Control Valve (IAC)
Intake Air Temperature (IAT)

Good luck!