2.5tdi eurovan swap and 5speed!

euro conversion

So I too am about to begin a euro conversion. My question for someone out there is,
does the entire exhaust system need to replaced or do I just remove the catalytic converter?
Also, can I use the existing 5 speed tranny from the gasser? One person mentioned needing a different 5th gear for the diesel.
I'll post some pics once I start this project.
Thanks!

BCL said:

So I too am about to begin a euro conversion. My question for someone out there is,
does the entire exhaust system need to replaced or do I just remove the catalytic converter?
Also, can I use the existing 5 speed tranny from the gasser? One person mentioned needing a different 5th gear for the diesel.
I'll post some pics once I start this project.
Thanks!

Click to expand...

the diesel's seem to have the same (except for the diesel 'cat) downpipe with the 'flexi' or inverted bell connection onto the manifold / turbo outlet, if your van is petrol then it will probably need a diferent downpipe?
as to the 'cat', if you can escape emission rules then bin it

Gearbox info might help work out ratio diferences? (stolen from another forum

The 02B Gearbox is a beefed up 5-speed gearbox derived from the new cable operated 02A gearbox first found in the '89 Corrado, '88 Passat and Mk2 Golf G60 and grew into the 02Z gearbox found in the 4-cylinder T5 models.
Gear selection in the Transporter is relayed by heavy duty rods rather than cables and the final drive casings are enlarged to house a bigger - and stronger - crown wheel and pinion.
The Transporter clutch is either actuated hydraulically by an externally mounted slave cylinder (on all rhd vehicles, all vehicles with additional heater and all vehicles destined for Canada) or mechanically by a self adjusting cable.

Click to expand...

Gearbox Code Type Oil Capacity (Litres) Final Drive 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Reverse Gear Speedo Year
AFK 02G 2,3 82:21=3,905 43:11=3,909 36:17=2,118 35:26=1,346 35:36=0,972 35:48=0,729 37:23x23:10=3,700 13:22=0,591 08/9507/99
AFL 02G 2,3 82:21=3,905 43:11=3,909 36:17=2,118 35:26=1,346 35:36=0,972 35:48=0,729 37:23x23:10=3,700 13:22=0,591 08/9507/99
AYD 02B 2,5 83:18=4,611 34:9=3,778 36:17=2,118 40:28=1,429 35:34=1,029 36:43=0,837 19:9x36:20=3,800 12:20=0,600 06/9008/91
AYE 02B 2,5 84:17=4,941 34:9=3,778 36:17=2,118 39:29=1,345 34:35=0,971 34:45=0,756 19:9x36:20=3,800 12:20=0,600 06/9008/91
AYF 02B 2,5 83:18=4,611 34:9=3,778 36:17=2,118 39:29=1,345 34:35=0,971 34:45=0,756 19:9x36:20=3,800 12:20=0,600 06/9008/91
AYG 02B 2,5 84:17=4,941 34:9=3,778 36:17=2,118 40:28=1,429 35:34=1,029 36:43=0,837 19:9x36:20=3,800 12:20=0,600 08/9108/92
CCW 02B 2,5 83:18=4,611 34:9=3,778 36:17=2,118 35:24=1,458 35:34=1,029 36:43=0,837 18:9x36:20=3,600 12:20=0,600 08/9108/92
CCX 02B 2,5 84:17=4,941 34:9=3,778 36:17=2,118 34:25=1,360 34:35=0,971 34:45=0,756 18:9x36:20=3,600 12:20=0,600 08/9108/92
CCY 02B 2,5 83:18=4,611 34:9=3,778 36:17=2,118 34:25=1,360 34:35=0,971 34:45=0,756 18:9x36:20=3,600 12:20=0,600 08/9108/92
CCZ 02B 2,5 84:17=4,941 34:9=3,778 36:17=2,118 35:24=1,458 35:34=1,029 36:43=0,837 18:9x36:20=3,600 12:20=0,600 08/9108/92
CHP 02B 2,5 83:18=4,611 34:9=3,778 36:17=2,118 35:24=1,458 35:34=1,029 36:43=0,837 18:9x36:20=3,600 12:20=0,600 08/9208/93
CHR 02B 2,5 84:17=4,941 34:9=3,778 36:17=2,118 34:25=1,360 34:35=0,971 34:45=0,756 18:9x36:20=3,600 12:20=0,600 09/9208/93
CHS 02B 2,5 83:18=4,611 34:9=3,778 36:17=2,118 34:25=1,360 34:35=0,971 34:45=0,756 18:9x36:20=3,600 12:20=0,600 09/9208/93
CHT 02B 2,5 84:17=4,941 34:9=3,778 36:17=2,118 35:24=1,458 35:34=1,029 36:43=0,837 18:9x36:20=3,600 12:20=0,600 09/9208/93
CPV 02B 2,5 73:16=4,563 34:9=3,778 33:16=2,063 31:23=1,348 29:30=0,967 30:39=0,769 18:9x36:20=3,600 12:20=0,600 01/942/95
CPW 02B 2,5 73:16=4,563 34:9=3,778 33:16=2,063 31:23=1,348 30:29=1,034 31:37=0,838 18:9x36:20=3,600 12:20=0,600 01/9412/95
CRL 02B 2,5 83:18=4,611 34:9=3,778 36:17=2,118 35:24=1,458 35:34=1,029 36:43=0,837 18:9x36:20=3,600 12:20=0,600 09/9312/95
CRM 02B 2,5 84:17=4,941 34:9=3,778 36:17=2,118 34:25=1,360 34:35=0,971 34:45=0,756 18:9x36:20=3,600 12:20=0,600 09/9312/95
CRN 02B 2,5 83:18=4,611 34:9=3,778 36:17=2,118 34:25=1,360 34:35=0,971 34:45=0,756 18:9x36:20=3,600 12:20=0,600 09/9312/95
CRP 02B 2,5 84:17=4,941 34:9=3,778 36:17=2,118 35:24=1,458 35:34=1,029 36:43=0,837 18:9x36:20=3,600 12:20=0,600 09/9312/95
DCU 02B 2,5 73:16=4,563 34:9=3,778 33:16=2,063 32:22=1,455 30:29=1,034 31:37=0,838 18:9x36:20=3,600 12:20=0,600 01/9605/97
DCV 02B 2,5 84:17=4,941 34:9=3,778 36:17=2,118 34:25=1,360 34:35=0,971 4:45=0,756 18:9x36:20=3,600 12:20=0,600 01/9605/97
DCW 02B 2,5 73:16=4,563 34:9=3,778 33:16=2,063 31:23=1,348 29:30=0,967 30:39=0,769 18:9x36:20=3,600 12:20=0,600 01/9605/97
DCX 02B 2,5 84:17=4,941 34:9=3,778 36:17=2,118 35:24=1,458 35:34=1,029 36:43=0,837 18:9x36:20=3,600 12:20=0,600 01/9605/97
DJZ 02B 2,5 83:18=4,611 34:9=3,778 36:17=2,118 34:25=1,360 34:35=0,971 4:45=0,756 18:9x36:20=3,600 12:20=0,600 01/9605/97
DKA 02B 2,5 83:18=4,611 34:9=3,778 36:17=2,118 35:24=1,458 35:34=1,029 36:43=0,837 18:9x36:20=3,600 12:20=0,600 01/9605/97
DQG 02B 2,5 73:16=4,563 34:9=3,778 33:16=2,063 32:22=1,455 30:29=1,034 31:37=0,838 18:9x36:20=3,600 12:20=0,600 06/9709/00
DQH 02B 2,5 73:16=4,563 34:9=3,778 33:16=2,063 31:23=1,348 29:30=0,967 29:39=0,744 18:9x36:20=3,600 12:20=0,600 06/9709/00
DQJ 02B 2,5 84:17=4,941 34:9=3,778 36:17=2,118 34:25=1,360 34:35=0,97 34:45=0,756 18:9x36:20=3,600 12:20=0,600 06/9709/00
DQK 02B 2,5 84:17=4,941 34:9=3,778 36:17=2,118 35:24=1,458 35:34=1,029 36:43=0,837 18:9x36:20=3,600 12:20=0,600 06/9709/00
DQL 02B 2,5 83:18=4,611 34:9=3,778 36:17=2,118 34:25=1,360 34:35=0,971 34:45=0,756 18:9x36:20=3,600 12:20=0,600 06/9709/00
DQM 02B 2,5 83:18=4,611 34:9=3,778 36:17=2,118 35:24=1,458 35:34=1,029 36:43=0,837 18:9x36:20=3,600 12:20=0,600 06/9709/00
DQR 02B 2,3 71:18=3,944 43:11=3,909 36:17=2,118 35:27=1,296 34:38=0,895 34:49=0,694 37:23x23:10=3,700 elektr. 07/9906/03
DRH 02G 2,7 74:15=4,933 43:10=4,300 37:16=2,313 35:26=1,346 33:38=0,868 32:51=0,627 37:23x23:10=3,700 elektr. 07/9906/03
DUH 02B 2,5 72:17=4,235 34:9=3,778 33:16=2,063 31:23=1,348 29:30=0,967 29:39=0,744 18:9x36:20=3,600 12:20=0,600 06/9809/00
DUJ 02B 2,5 72:17=4,235 34:9=3,778 36:17=2,118 30:23=1,304 28:31=0,903 28:40=0,700 18:9x36:20=3,600 12:20=0,600 06/9809/00
DXZ 02G 2,3 82:21=3,905 43:11=3,909 36:17=2,118 35:26=1,346 35:36=0,972 35:48=0,729 37:23x23:10=3,700 13:22=0,591 07/9906/03
DYA 02G 2,3 82:21=3,905 43:11=3,909 36:17=2,118 35:26=1,346 35:36=0,972 35:48=0,729 37:23x23:10=3,700 13:22=0,591 07/9906/03
EEZ 02G 2,3 71:18=3,944 43:11=3,909 36:17=2,118 35:27=1,296 34:38=0,895 34:49=0,694 37:23x23:10=3,700 elektr. 05/9807/99
EFA 02G 2,7 74:15=4,933 43:10=4,300 37:16=2,313 35:26=1,346 33:38=0,868 32:51=0,627 37:23x23:10=3,700 elektr. 03/9807/99
EVU 02B 2,5 73:16=4,563 34:9=3,778 33:16=2,063 32:22=1,455 30:29=1,034 31:37=0,838 18:9x36:20=3,600 12:20=0,600 09/0006/03
EVV 02B 2,5 84:17=4,941 34:9=3,778 36:17=2,118 34:25=1,360 34:35=0,971 34:45=0,756 18:9x36:20=3,600 12:20=0,600 09/0006/03
EVW 02B 2,5 73:16=4,563 34:9=3,778 33:16=2,063 31:23=1,348 29:30=0,967 29:39=0,744 18:9x36:20=3,600 12:20=0,600 09/0006/03
EVX 02B 2,5 84:17=4,941 34:9=3,778 36:17=2,118 35:24=1,458 35:34=1,029 36:43=0,837 18:9x36:20=3,600 12:20=0,600 09/0006/03
EVY 02B 2,5 83:18=4,611 34:9=3,778 36:17=2,118 34:25=1,360 34:35=0,971 34:45=0,756 18:9x36:20=3,600 12:20=0,600 09/0006/03
EVZ 02B 2,5 83:18=4,611 34:9=3,778 36:17=2,118 35:24=1,458 35:34=1,029 36:43=0,837 18:9x36:20=3,600 12:20=0,600 09/0006/03
EWA 02B 2,5 72:17=4,235 34:9=3,778 33:16=2,063 31:23=1,348 29:30=0,967 29:39=0,744 18:9x36:20=3,600 12:20=0,600 09/0006/03
EWB 02B 2,5 72:17=4,235 34:9=3,778 33:16=2,063 30:23=1,304 28:31=0,903 28:40=0,700 18:9x36:20=3,600 12:20=0,600 09/0006/03
FJS 02G 2,3 82:21=3,905 43:11=3,909 36:17=2,118 35:26=1,346 35:36=0,972 35:48=0,729 37:23x23:10=3,700 13:22=0,591 03/0106/03
FTV 02G 2,3 74:15=4,933 43:10=4,300 37:16=2,313 35:26=1,346 33:38=0,868 32:51=0,62 37:23x23:10=3,700 13:22=0,591 04/0106/03

sorry for the blatant sledge-hammer of useless info

Rich.
__________________

euro

Oh man Zed, you are a plethora of information. Lol. Unfortunateley i don't speak that language. I just need to know if i can use the tranny that is in my gasser euro for a diesel swap or not.
Thanks!

Fresh are you going to leave us hanging?

BCL said:

Oh man Zed, you are a plethora of information. Lol. Unfortunateley i don't speak that language. I just need to know if i can use the tranny that is in my gasser euro for a diesel swap or not.
Thanks!

Click to expand...

it will bolt up but you'll be revving over 3500 rpm at most highway speeds

a popular mod over here with the T4 van is to use the golf tdi's 5th gear pair (.71?? Ratio??) but this is sometimes the same ratio as the origonal van item so check what ratio you have (between bellhousing & gearlinkage on top of box, 3 letter code stamped into casing in a 1" x 2" machined surface)

For mine I have a 2.4d gearbox (van was a 1.9D so 60hp now 1Z 90hp t'die ) that has a higher final drive so altogether calmer

Rich.

Lets not hijack gresh's thread too much...gresh you out there!? I'd love to see an update! Got that thing on the road yet?

Sorry

Didn't realise

Rich.

swap

I might have to start a thread for my own conversion because I see lots of questions in my future.
I too would like to know about this conversion by Gresh!

Sorry folks Had some bad things happen recently, wrecked tdi head and a loss in our family has slowed life a bit.
The timing was off and the pistons were just touching valves enough to smash the lifters. I had to order a head and gasket set from Germany. not cheap. the timing was off in the video of the engine running
just didn't know it until I pulled up vcdc to check timing. I cant believe it still ran in that condition. the timing issue also explains the hard starting and smoke from exhaust. it is running now very smooth pics and more details to come

I may have to take a trip to Dufur sometime. Or, if you aren't doing anything June 13, I will be having a GTG down here. Would love to have you swing by.

I just found this thread and AM VERY INTERESTED. I just bought a '96 VW/Winnebago Rialta. For those of you who don't know it's a 21-foot mini-motorhome based on a T4 chassisl. In '95-'96 these came with a 2.5 5-cylinder gasser motor and mine routinely gets 15mpg, and with an auto trans is slow/underpowered to say the least. The 2.5 TDI with a 5-speed swap sounds like an expensive no-brainer but one I'm seriously considering. What did you pay for the engine from Germany? What would you anticipate the mpg to be with appropriate gearing? The Railta weighs 6,000 lbs.

rv

I spent 5 k on my swap. for your situation I think it would work well with a mild tune.
enough to get down the road faster than you do now.
I anticipate 30-35mpg with my rig.

gresh125 said:

Sorry folks Had some bad things happen recently, wrecked tdi head and a loss in our family has slowed life a bit.
The timing was off and the pistons were just touching valves enough to smash the lifters. I had to order a head and gasket set from Germany. not cheap. the timing was off in the video of the engine running
just didn't know it until I pulled up vcdc to check timing. I cant believe it still ran in that condition. the timing issue also explains the hard starting and smoke from exhaust. it is running now very smooth pics and more details to come

Click to expand...

You replaced the whole head? What did you do with the old one? Can I have it?

its going strong

Well we have had the van running and driving for sometime now and figured we have about 3000k on the swap so far and no one issue well one flat tire, and I have a suspicion it is unrelated to the diesel swap.

It has plenty of power to get around. Very smooth and quiet inside.
we are getting around 30 +/- mpg. My wife is very pleased .
we have spent a night in it with the kids what a blast.

Here are some pics I got a serp belt for it and it was for a 95 gasser ev and was about an inch too short so I removed the plastic idler pulley and reproduced it but a smaller diameter and out of aluminum. it fit nicely
and now I can get a belt off the shelf here in the u.s. if it ever fails.

van


fits great better than plastic too!

Nice job. This is cool!

Glad to see you got her on the road! I want this to be my next project

Nice!

Very nice! I am about to do my first '93 EV swap. Wish I had a fancy metal lathe. lol.
Thanks for all the info!

I like your idler pulley! On my car, I replaced the plastic idler pulley with one made for a 1985 Ford 5.0 Mustang; had to turn a new adapter piece to get it aligned properly, but otherwise it was a bolt-in.

5000 miles on swap

well my wife managed to put 5000 miles on the swap so far and its been great cold ac in the summer has been great. kids love it to. I call it the time machine because you can go in the back and lay down during a road trip and boom you wake up and your there. As long as your not driving of course. you guys wanted a comparison on power compared to the 4 cyl swaps. I cant compare as I havent drove one yet. however I will say that this thing in stock form is not a rocket but way faster than the old vanagon we had in the past. I think that the 5cyl is a better swap in the long run b/c I dont have to chip this engine and bump the power up to get it to push the van around therefore I think this engine will last longer than a 4 cyl tuned up to make more power and be req to push this 5k van around just my 2 bucks : teeth

Did you have any trouble getting it registered and getting it inspected? Did they just change the title to diesel for you? I'm looking at a swap myself from gas to diesel in another vehicle, and this is the part that is giving me issues right now.