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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old July 10th, 2018, 20:57   #1
svseeker
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Default Bellhousing for 95' 1.9 AAZ TD

Howdy. Accept my apologies because I barely know enough about VW engines to ask this question. But we have what I believe to be a 1995 VW 1.9 AAZ turbo diesel engine out of a Passat that we have installed in a jet boat. We make an adapter plate so the drive shaft is bolted onto the back of the flywheel, and then fabricated a mount for the starter which would normally be bolted onto the bell housing. The problem is that the starter frequently hanging up after the engine starts and it's not very long before we have destroyed the gear teeth on the starter. We have tried but have not been successful correcting the problem with our fabricated starter mount, so we have decided to try an locate a transmission that we can then cut away the bell housing portion so we can more accurately mount the starter. The problem is that we are not sure which cars or years might be suitable matches for our engine. We need to know the various makes and years that will fit this engine and be assured that the starter will align properly with the flywheel. Hopefully there is a number of modes and years that will fit.

Here is a link to a video that shows the engine being installed. Skip to 4:50
https://youtu.be/ef3fKUV9Ka8?t=294

And thanks for your assistance. --Doug
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Old July 11th, 2018, 02:51   #2
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The B4 Passats all used the O2A series transmissions. I'm confident the O2Js also used this same starter. Bosch SR0408X is the part number.
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Old July 11th, 2018, 04:13   #3
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Doug

The bell housing bolt "pattern" on VW in-line 4 cylinder engines has the same pattern all the way back to 1974 and including up thru 2006 and maybe later, gasser or diesel! And, the starter Mogly listed will work ...
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Last edited by AndyBees; July 11th, 2018 at 04:19. Reason: Clarification
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Old July 11th, 2018, 16:45   #4
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That is good news. If you know, have there been any changes in location of the fly wheel that would cause the starter to be located too far forward or back? I have an offer for a 99 Beetle down in Texas. It just seems strange that it might fit.
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Old July 11th, 2018, 19:19   #5
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The flywheel from any model in those ranges will work on any engine.. no changes. The teeth on the flywheel are in the same place in relation to the start engagement. However, the flywheel used on the early models (MK1) is substantially different. A late (MK4, MK5) model flywheel will bolt up and work perfect on the older engines but can only be used in the later transmissions as the clutch operation is also entirely different in the older set-ups.
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Old July 25th, 2018, 15:18   #6
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Thank you folks. It seems to be working fine. The bell housing is say to be from a 99 VW Beetle but that starter was not a match. The starter fit a 92 VW Corrado G60 with a 1.8L.

https://www.facebook.com/doug.jackso...2412583437555/
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Old August 1st, 2018, 12:37   #7
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Quote:
Originally Posted by AndyBees View Post
Doug

The bell housing bolt "pattern" on VW in-line 4 cylinder engines has the same pattern all the way back to 1974 and including up thru 2006 and maybe later, gasser or diesel! And, the starter Mogly listed will work ...
1974 (1972 if you go Audi) to 2019 for I4 bell housings and cranks.
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Old August 1st, 2018, 12:38   #8
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02A and 02J starters interchange. However, you shouldn't use a gasoline starter on a Diesel as you will never spin it over fast enough.
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Old August 7th, 2018, 11:37   #9
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https://youtu.be/DhnrmryQo7s
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