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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 August 12th, 2019, 07:57   #1
Join Date: Jan 2015
Location: Wales (UK)
Default UK based B3v, mk2 Golf & t4 (Eurovan) tdi's

Okey, I admit it, I've too many tdi'd vw's
I've been on here for 4+ years but as a reader & lurker so don't post much, thought it about time I posted some waffle

'89 B3 & '95 t4

same '89 B3, '87 mk2 Golf & the blue '92 B3 is stripped as a parts car (even kept panels including rear wing assemblies)
my late (for UK market) '93 B3v, was 1.8i singlepoint injection now AHU tdi'd using a '95 B4 donor, sorry but I guess everyone's seen a sorta standard install

just a comment on t4's in the UK

my '89 B3 again, also one of my 200tdi Landrover Discovery's and my '91 Eunos Roadster (Mazda Miata or MX5), the Eunos is staying with the 1.6 petrol engine as I don't think theres a high enough final-drive available to work with a low-revving tdi in it's chassis :-D
some B3 related wanderings, admittedly incomplete history of my time with them but something in writing
I've broken / parted probably 15 B3 & B4 cars but one day will find another with the uncommon climatronic (had a setup in the first B4 that was donor for the t4 - stupidly kept the clima electronics but binned the heaterboxes and they are hard to find here )
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Old August 14th, 2019, 18:46   #2
Veteran Member
Join Date: Mar 2014
Location: St.Paul, MN
TDI(s): 02 golf ALH
Fuel Economy: 42 stock, 47-49 now

Originally Posted by Zed. View Post
the Eunos is staying with the 1.6 petrol engine as I don't think theres a high enough final-drive available to work with a low-revving tdi in it's chassis :-D
with a bigger turbo a 1.9 will breathe from 3k out to 6k rpm (and beyond, but I haven't been there yet)

Nice stable of TDIs, any pics of the eurovan engine bay? don't see a huge number of them over here, much less with the correct motor in them
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Old August 15th, 2019, 10:30   #3
Join Date: Jan 2015
Location: Wales (UK)

sorta looks lost in there

used a '95 B4 Passat as tdi donor, car had 314.000+ miles behind it & believe on origonal engine!
conversion from origonal 1X (1.9D) engine so used t4's sump/pickup/dipstick & tube / engine & driveshaft mounts / coolant pipework etc. and a B5.5 Passat 'pd130' inlet manifold to have a bolted intercooler pipe flange (less rubber joints& possible leaks).
also used the car turbo & manifold to have a 'low-mount' and more room underbonnet and ease of maintanance

for the fly-by-wire throttle, vw partsbin as the '96-'99 t4's had a diferent throttle pedal & suitable bracket to mount the potentiometer.

as to intercooler, used the vw partsbin again, t5's have an oem fit front-mount that sits nicely between the grille & radiator with minor trimming of the headlamp surround and easily made brackets (although more common with the t4 numpty's is to use the huge intercooler from an LT35 / mercedes Sprinter )

90hp, cruise control & mfa dash cluster (from the donor B4) with 40+mpg so cannot complain - even welded the 'top' filler section of the t4's origonal 1X camcover onto the 1Z tdi's item for the extended oil filler neck, it's the little things like this that make a conversion liveable with :-)

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Old August 16th, 2019, 06:01   #4
Join Date: Jan 2015
Location: Wales (UK)

been working on my tdi'd 1987 mk2 Golf (brakes siezed & needs it's first bit of welding - patch under the rear seat :-? ) and moving stuff around in the unit...
empty space

a rather 'odd' place to find rust? was starting to rot from below so time to chop it out & repair :|

the mighty '90hp' AHU tdi engine, about 175'/lbs torque standard so not slow in the light mk2 lightly fettled & de-restricted so economical & fun as a daily 8-)
one day I'll tidy the underbonnet, I have a diesel airfilter box to fit & replace the inlet manifold with one from a 'pd130' Passat to have a bolted flange connection to the intercooler pipework (not a few 'jubilee' clips!) - one day....

the 'office', loads of rare ish bits on this car, the cruise stalk (NOS in box) was a nice find as it's only used for a year or so compared to the earlier & later stalks also the td dash cluster as it has an alternator triggered tacometer to work with the diesel engine (the car is running an ecu controlled 'fly-by-wire' throttle setup but mk2 golf's didn't have ecu triggered tacometers just ignition-coil triggered so this is a 'get-around')
also, Cruise working on a cable speedometer, used a hall-sensor on the rear of the speedometer to supply the vss to the ecu.
Ce1 wired car with adapted Ce2 engine loom, the car actually became tdi powered 3 years ago yesterday
must find intrest to weld the t4, it's mot expired in january & has been sitting in the unit since while still insured

another better photo of the t4's enginebay

more waffle to come....


Last edited by Zed.; August 16th, 2019 at 06:10.
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