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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 February 11th, 2011, 22:19   #1
caddywompus
 
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Default 99 Eurovan T4 TDI conversion

This rig is a '99 EVC that showed up a few weeks ago for one of our TDI conversions. We've done a couple '93 EVs but this is the first '99 we've tackled. We are in the process of converting it with a built AHU engine and an EWB 02B 5-spd manual trans from europe.



Modding AHU engine to ABL protocol. Drilling out dipstick hole:


R side engine bracket bolt holes being drilled/tapped to 10m x 1.50.




R side T4 4-cyl engine bracket fitted:


PD150 pistons and Rosten rods:


Installed in AHU block:


T4 oil pump and oil pan baffle installed:


T4 oil pan installed, short block complete:
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Old February 11th, 2011, 23:03   #2
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Looks good so far. Will the main challenge be the wiring then?
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Old February 12th, 2011, 08:34   #3
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I'll be watching this closely! A Tdi powered, manual trans T4 is pretty close to perfection! Are you going to have this long enough to report mileage once it is finished?
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Old February 13th, 2011, 10:19   #4
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Wiring is fairly straight forward using a 1Z harness, since it's basically the same VAG platform electronically as first generation TDIs. This means it isn't exactly plug-n-play, but close. The two things that are a little more complicated are integrating & wiring the TDI/VR6 cluster, and installling the pedal potentiometer. But it's a lot easier than a Vanagon for sure.

For future reference, we maintain a shop blog where we have alot more pics as well as an archive of past TDI conversions, Eurovan and Vanagon alike: http://www.greaseworks.blogspot.com/

Here are a few more pics of this conversion:

Clutch pedal assembly install.


Pedal potentiometer install (top of pedal assembly).





More to come....
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Old February 13th, 2011, 10:23   #5
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We will have MPG reports back from the customer but what we're expecting based on past experience is ~30-35mpg HWY.
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Old February 15th, 2011, 06:06   #6
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Is the half cut going into your Weekender Justin or a customers? Its the I5 2.5L right?
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Old February 24th, 2011, 14:25   #7
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Looks good, It's good to see that your doing the build right with the strong internals. It should be an awesome ride when finished. About two months ago I was able to do some work on a 2.5L TDI hightop, it was the shorter wheelbase, but was sure a nice ride. I think if I were to start another tdi swap it would be similar to yours. It should be a lot quieter than a TDI Vanagon at highway speeds which is very appealing.

Good work.
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Old February 28th, 2011, 22:03   #8
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Default AHU eng installation

The T4 syncro front clip is one I bought hoping to find a customer who wants a dreamy T4. I don't plan on installing that in my EV--it'd be fun for bragging rights, but that only goes so far: I would hate the MPG penalty with the syncro and 5-cyl, and be troubled by the 5-cyl unresponsiveness in the low RPMs. I'm just really happy with my 130 whp AHU T4 weekender what can I say?

Here are some pics of the final eng prep and install into the '99 EVC, with more details/pics here:



AHU flywheel installed.


Sachs G60 press. plate and clutch disc installed.



R side engine bracket/mount. Eng waiting to be timed.



EWB trans mated and eng timed. Rolled into position on elevated dolly.



L side eng/trans showing L mount/bracket.


R side eng w/mount & bracket on upper L of pic


Van being lowered onto engine.


Mounts line up and are bolted to frame. Engine hanging on its own now.


View from R side eng compartment.

Lots more stuff to connect and button up, but we're getting really close!!
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Old March 1st, 2011, 06:47   #9
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Wow! Nice work!

Like that custom made dolly for maneuvering the engine in place! That sort of ingenuous work is, well, naturally part of the project!
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Old March 1st, 2011, 09:17   #10
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What transmission/shift assembly bits are you using for this?
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Old March 1st, 2011, 23:09   #11
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Thanks AndyBs! We are using an EWB 5spd trans imported from Germany, along with the later style L tranny mount and the pendulum lwr/rear trans. mount. For tranny bits we're using early T4 02B 5-spd shifter rods/lever box, etc., available domestically.
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Old March 2nd, 2011, 06:10   #12
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Awesome, thanks.

Looking good. I've owned both a 91 Syncro and currently a nice T-Red 2003 T4, love the van but TDI and a third pedal really has always been a huge craving for me. Considered a half-cut 5cyl but this route probably makes a whole lot more sense and I know I can end up with a tune that would keep OBDII emissions scanners happy.

Good luck with finishing it up, please post more on it.

Thanks.
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Old March 2nd, 2011, 07:28   #13
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What axles are you using to mate with that EWB trans for the T4?
do you have the part numbers for the engine & tranny mounts to hang the 4 cylinder motor in the eurovan? is there a lower pendulum styl mount as well?
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Old March 2nd, 2011, 20:52   #14
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This could actually make eurovan's cool!! Very nice to see this documented. Are there any tranny options that wouldn't have to me brought over from way over there? VR trans?

I was under the impression the injector angle & therefore the combustion chamber placement in the piston on the PD's vs. AHU were different enough to make the pistons non-interchangeable? Or is it just their nozzles that can't swap.

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Old March 2nd, 2011, 20:52   #15
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R side A/T drive axle bolts up to the M/T, L side A/T axle is 10mm shorter than what it needs to be. I have an early T4 L M/T axle coming tomorrow AM and will let you know if it fits. As for mounts, all the eng/trans supporting brackets and mounts we used are the stock ones for the A/T VR6 (including lwr trans pendulum mount), with the exception of the R side engine bracket. I don't have this P/N handy at the moment but trust me, I searched the continent here in NA and it doesn't exist here as VW never sold a 4-cyl diesel T4 in NA. We import this part from our euro parts supplier where they are still available new from VW, and usually we have several on the shelf.
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