I have a 90 track 4X4 2 door 5spd.
Got my kit from acme about $1100 with a few extras.
My motor I got the 70hp turbo off ebay from thomas in montclair, ca about $1500~
Make sure you get the exhaust flange kit and first 6-12" of stock exhaust pipe, special flange.
Make sure you have a good set of metric sockets, and a set of metric socket allen wrenches.
He is a typical german engineer, but a great source of info, imports engines himself.
So get an engine stand and cherry picker, going to need it for a few weeks.
You will need 3-4 bolts 10mmX1.5 from lowes or home depot 70-90mm to mount on engine stand.
Acme gives a new oil pan and oil pump, that goes in first.(make sure order a new gasket, acme does not supply, about $11 at pepboys.
Before putting on engine stand remove all flywheel and clutch and stuff, uses 12 point 9mm socket.
Remove two stud flanges? off bottom of engine that line up to transmission.
You will also need to trim trans mounts to mate up.
Thats a pain because this is my daily driver, so plan on not driving your zuk for a week if youa re fast, a month if you are like me.
Remove all timing belt covers on front of engine, replace timing belt and tensioner (buy from Thomas or pepboys)
The scary part is you have to cut off part of the engine crank, haven't done that yet.
You then have to cut the oil return line from the turbo, replace short run with rubber hose (acme part) move zuk alternator to under turbo with acme bracket, still doing that, bolt on flywheel stripped need to drill and remove.
A note about vw diesels. They have no timing marks.
Jeff at acme suggests eyeballing #1 piston and removing valve cover eyeballing valves...still working on that one.
Organize a muffler shop to do a full exhaust with muffler $200~
Thomas suggests disconnecting in tank fuel pump as the vw has its own fuel pump, however put a 2.5psi fuel pump in front of the diesel filter in engine compartment(or on tank using stock 12V wires) as the new diesel low sulfur (biod OK) doesn't flow as nice on the older mechanical diesel pumps.
You will need some fuel inlet and return tank lines (have not done that yet).
The pro's suggest a viton rebuild kit for injectors and pump and lines if using bio100, about $70~ on ebay.
Are you scared yet?
If not come to my home and help me finish mine.
PS? I have a 1.6L TBI with rebuilt top end for sale soon, 5spd.
