1g intake on a 2g? 1g engine swap?

[Infamous33]

I had a customer tow in a 95 tsi. He couldn't get it to stay running, now it's running but there is an enormous vacuum leak at the intake manifold gasket.
My confusion is this. I'm trying to help him figure out if this has had an engine swap, so he will know what year to buy parts for. Here are a couple questions
Did a 2g come with a CAS?
Where does the ignitor mount on a 2g? This one currently just lays ontop of the fuel rail.
Where does the coolant line at the oil cooler return? This one had the return piped into the overflow nipple. WTF
Is there a date/date code on the block anywhere?

I'm fairly certain this is a swap, and im not sure how or if I can find out what year the engine is. There are a few other indicators that are fueling my suspicions, but you get the idear.

 

[96talon4g63]

Do you have a pic of the Cas. If it's a 95 then most likely it's got a 6 bolt swap. 97-99 had the Cas mounted on the left side of the head

 

[19Eclipse90]

Did a 2g come with a CAS?

Yes. On the '95-'96 models, it was behind the intake cam gear on the belt side. On later 2Gs, it was on the passenger side of the head (see below). The two can be interchanged but it takes a little extra work: http://www.dsmtuners.com/forums/newbie-forum/405089-98-spyder-wiring-harness-question.html#post152614167

Where does the ignitor mount on a 2g? This one currently just lays ontop of the fuel rail.

That sounds correct as long as it is actually bolted down to something. However, you cannot judge what an engine is by its manifolds, valve cover, thermostat housing, or oil filter housing.

Virtual Tour of the DSM Engine Bay - Quadrant map -- you can trace the plug wires back to find that is in the location you described; you will also note that this particular example has a late model 2G CAS.

Where does the coolant line at the oil cooler return? This one had the return piped into the overflow nipple. WTF

From this, it sounds like it has a mismatched thermostat housing. The first diagram below is of a 2G. The other pictures will help you figure out what thermostat housing it is.

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Is there a date/date code on the block anywhere?

Yes. http://www.dsmtuners.com/forums/cylinder-head-short-block/390960-block-identification.html

Here's a bit more information to figure out what block it is: http://www.dsmtuners.com/forums/cylinder-head-short-block/400868-6bolt-7bolt-main-cap-swap.html#post152575289

And here to figure out what head it is: http://www.dsmtuners.com/forums/newbie-forum/404339-how-distinguish-7-bolt-head-6-bolt-non-turbo-head-6-bolt-turbo-head.html

 

[Infamous33]

Here is the update on my issues.....

Turns out it is certainly a 1g head and intake, the ports are large and the gasket that I used was for the 90-94... Good part was this, fel pro managed to mess up and put 2 gaskets in the box I got today !!! I now have the intake gasket for when I take the intake off my 90 TSI (woohoo, I win a $5 gasket for my troubles

This car already blew a bypass hose while I was checking for vacuum leaks at the fuel rail and intake, I have the boils on my chest to prove it.
Now today, after replacing the intake gasket, finding out which head/intake this has, rerouting all the vacuum lines for THIS engine and replacing the busted starter...... Taaadaaaa
This thing smokes like Keith Richards.
Not sure if it's the engine or the turbo yet. Sorta got fed up with it after an 11 hour day. So, tomorrow I will bring in my spare turbo and see if that takes care of it. Only seemed to smoke after a road test w/boost....
Other than that, when it was towed in, it wouldn't even come close to holding an idle, and now it runs smooth as glass, with a side of blue smoke.
More updates to come. (Man I need to finish this so I can start on my OWN TSI)

ok, according to those pics, this has a 1g coolant housing. The update on the oil issue causes a question
My 'spare' turbo has a ton of shaft play, so I didn't bother. I took the intake hose off and there is a bunch of oil on the intake side. I'm not positive however I believe the only way for that to happen is a bad turbo seal right? All the years of working on cars, I have never had much experience with turbos. Guess that is because I spent most of my time working on domestics. Correct me if im wrong on the oil on the intake side anyone?

 

[tsiracing]

you are correct. but i had that same problem turns out the block i purchased was bored .20 over and the turbo was actually good :O

 

[99talongsx]

i had my turbo seals go bad and it was the scenario however this was a t25 on a stock 2g with 127k on it