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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 September 12th, 2017, 15:07   #1
Josh_WA
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Join Date: May 2015
Location: Mountlake Terrace WA
Fuel Economy: EV 30+mpg, Jetta 40+mpg
Default TDI 1Z to 93 Eurovan (budget build)

Poor man’s 93 Eurovan MV TDI conversion
Here we go again. I previously converted a 93 MV weekender for my use via this thread.
http://forums.tdiclub.com/showthread.php?t=443865/

My goal on that build was to spend about $2k for the conversion. I think I ended up spending about $2300. This time my goal was to again spend around $2k, but to also include the van.

Earlier this summer I can across a great deal on a rear wrecked B4 Passat that somehow couldn’t pass up. I pulled the car apart and saved up the conversion parts I need for another VW Eurovan (T4a) conversion. I’ve sold enough parts to net a free 1z engine and parts needed. The Passat had the timing belt changed about 10k miles prior to the rear ending, so I’m forgoing changing belts and rollers if they appear good. I’ll do some inspection on the rotating items as I clean up the engine. The turbo unfortunately needs to be replaced. The whole backside of the engine has a nice coating of oil. The nice thing about going with the 1z from a Passat, is that the gauge cluster is physically the same as the Eurovan cluster. Also, the wiring harness for the 1z is not integrated with the lighting harness of the car, so the wiring is a little cleaner to begin with. I have more parts to sell, but as of now I’m at +$150 with the wrecked Passat purchase.

Passat parts needed for the conversion:
Engine
Engine accessories, including turbo
Coolant hoses and reservoir
Engine wiring harness
Matched ECU
Gauge cluster
Fuel lines
https://flic.kr/p/Y4v6bN

Just recently a van came on the market that would be an ideal candidate for my budget build. There are usually plenty of inexpensive manual transmission GL models that come up, but I was waiting for a manual MV. This one was going for cheap because it’s only running on 4 out of 5 cylinders. $500 later, I’m sweating home on 4 cylinders, to avoid a tow. I’m again going with a stock manual transmission. This one being a CHP this time, but will changing out 5th gear for the .756 in the Passat transmission. Stock 5th is .8xx. With, the van, I’ll be pulling out what is saved from above, to be replaced. The van itself is in fair shape aside from the slider door that I will be replacing. The inside needs a trim piece and just a general cleaning, but is not too bad. I can get those pieces from a local guy. That brings my van price to about 650.
https://flic.kr/p/XoFyHQ

The 3rd part of this puzzle of course are the European parts to make this bolt right in. The 1z and AHU engines are of the same block build as the ABL na diesel that is available in Europe. Frans will be supplying these parts again. Costing about $600.

4cyl transmission carrier 02B409905K
lower timming belt cover 028109127H
Oil dip Stick/housing 028115629E, N90461401, 044115611F, N 028 224 01
Oil filler neck and cap 044115308A/070115319
Sump (oil pan) 044103601D
Transmission upper cover plate 044103647B

right-side engine mount 028199207E.
lift pump (fuel tank pump) 701919813B


So far I’m at $1150 in cost. Additional $s to be spent mostly on the turbo, clutch package, and exhaust welding.
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Last edited by Josh_WA; September 12th, 2017 at 15:08. Reason: spacing
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Old September 12th, 2017, 15:15   #2
Josh_WA
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Last time this took me a good 6 months to complete. Started with an easy task of drill and tapping the bolt holes for the European passenger side engine mount.

These 3
https://flic.kr/p/Y4v6pd

Drilled out with 5/16 bit
https://flic.kr/p/XoFy17

Bottom tapped with m10 x 1.5. The stock size running through the mount.
https://flic.kr/p/YECvo6
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Old September 12th, 2017, 15:57   #3
Bobob729
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I always told my self if I ever get a van this will be what I do. Awesome to see others are doing this as well
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Old September 12th, 2017, 20:09   #4
therabbittree
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Awesome! Looking for a clean 2000 so wiring and cluster matches my 1z. 96 passat.


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Old September 13th, 2017, 04:34   #5
Josh_WA
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Quote:
Originally Posted by therabbittree View Post
Looking for a clean 2000 so wiring and cluster matches my 1z. 96 passat.
You'll need a 93 cluster trim to fit the 96 Passat cluster to a 97-03 eurovan. Or use an mk4 tdi cluster.
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Old September 13th, 2017, 05:40   #6
therabbittree
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From what ive seen the 93-2000 eurovans have the b4 passat style cluster. The 2001-2003 eurovans have the different dash and have mk4 style clusters. Thats one of the benefits of Using the 2000 older eurovan vs a 2001-2003 . The 01-03 do have better brakes and suspension etc


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Old September 14th, 2017, 05:45   #7
mogly
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Cool project. Budget builds are always fun.

2000 was a transitional year for the T4. I've seen some with the early middle 2 person bench with the corduroy upholstery and others with '01-03 upholstery and separate buckets.
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