Woo hoo, I'm link #1....
Anyway, I'll add this:
I was once working on a TDI swap FAQ, but got a little side tracked and never finished it. Here's where I ended up:
lots of people ask lots of questions, let's clear up some things:
-. What are the various TDI engines? 1Z, AHU, ALH, the new 8V PD (BEW) (2004+ G/J), and the new 2.0 16V PD (2004+ Passat)?
-. What are the differences between the engines?
The 1Z and AHU are TDI engines based on the earlier engine design, with the vacuum pump in the distributor hole running the oil pump.
The water pump is of the traditional style and operated by the accessory belt. The 1Z and AHU use a traditional wastegate turbo.
The ALH and PD engines are based on the block design that started with the A4/Mk4 body style. The oil pump is driven on a chain by the crank. The water pump in integral to the engine block, and is run by the timing belt. The ALH and PD engines use a variable-vane VNT turbo. The ECUs for the later engines incorporate VWAG's Immobilizer anti-theft system (with a few exceptions). The IMMO system requires matched keys and and IMMO controller (generally the instrument cluster) for the engine to operate.
The 1Z and AHU engines are generally easier to install into the earlier style chassis due to changes in the block style and changes to the mounting bosses in the later style engines. The 1Z and AHU also don't have the IMMO system, so one doesn't need to install the instrument cluster or key reader.
-. What makes the TDI so special?
electronic controls, good power, great economy
-. Is there a way around the Immobilizer for the A4 engines?
Jeff Robertson @ RocketChip can flash the ECU to the industrial ECU (without IMMO) and then update to maps more appropriate for automotive uses.
Another option is to use a stand-alone IMMO box. I have yet to hear of it being done successfully.
The third option is to use the ECU from the 1998 New Beetle, as those ECUs didn't use the Immobilizer. (the early 81 pin ECUs)
-. General Rules of swapping:
If the car you are looking to swap into was available with that engine from the factory, it would be easier and cheaper to sell your car and buy one with that engine factory installed.
Alternately, buy a wrecked car of the same body style and swap over all of the required pieces.
3. Can I swap a TDI into my:
3a. A1 (Rabbit, Jetta 1, Scirocco, pickup)
Yes. TDI rabbit links
Rabbit TDI project, ALH
Rabbit TDI, AHU
3b. A2 (Golf, Jetta)
3c. A3 (Golf, Jetta)
The Jetta was available with the TDI. Use a wrecked Jetta for all the parts to convert a Golf. The A4 engine has been successfully installed into the A3
3d. A4 (Golf, Jetta, TT)
Buy a used one. It's too much work and effort to convert a car.
However, a TT TDI would be fantastic...
3e. B3 (Passat, Corrado)
3f. B4 (Passat)
Like the A4 cars, the B4 cars were available with the TDI. It's cheaper and easier to buy an OEM TDI than to build one.
3g. Audi A4,A6, B5 Passat
Available in Europe as TDIs. You'll have to do the research yourself.
2004+ Passats were available from the factory with 130HP 2.0PD TDIs.
This is an ongoing project for many people. There is a VanagonTDI mailing list on Yahoo Groups.
4. What transmission should I use?
B4s and A3s come with the 02A (3.16 FD)
A4s with 02J (3.38 FD), 02M (europe)
020 with (numerically) low final drive
All VW inline 4-cyl engines will bolt to VW inline-4 trannies.
For instance, 2003 20V 1.8T will bolt to a 1974 4-speed.
early Dodge Omnis had VW engines and VW transmissions, but with a 3.4 FD. It's only a 4spd though.
Your best bet is the A3/B4 O2A.
The most complicated swap is the 02M.
YOU WILL NOT BE HAPPY WITH YOUR 020. It'll rev too high for good mileage, and, uh, tic-tic-tic-boom.
02A, 02J convert to cable clutch, hydro clutch
02M - locate from Europe or specialty importers, hydro clutch
For the adventurous: DIY 6spd - search for Punkassjim on VWVortex
4a. What about the speedo?
Dakota Digital makes electronic calibrator boxes that work great for stepping up/stepping down the signal to run an electronic speedo.
The early 02A used a mechanical speedo, and those parts will pop into an O2J as well. As for calibration, I have no idea.
5. What about all the wiring?
There is alot of wiring with the TDI engine and its associated electronics.
Keep yourself organized and it shouldn't be an issue.
6. Is there a way to get around the Drive-By-Wire
The DBW is an integral part of the ECU controlled TDI. It's a non-issue, really. Six wires and it's done. There are more wires involved setting up the cruise control.
It is possible to install a hybrid manual pump on the VE engines.
With the manual pump it is possible to get more power from the engine, but you also lose the ECU controlled continuous fine-tuning of the engine, and controlling the VNT turbo becomes more complicated.
7. How much will it cost?
Depending on your source of the engine, the completed swap may cost you an aweful lot of money. Search around. www.car-part.com
The most economical way is to buy a wrecked car and then make money back parting out the parts you don't use in your swap.
-. What bits will I need? (engine)
engine, engine wiring harness, intake manifold, exh manifold, downpipe
turbo, maf, iat/map sensor, dbw pedal, ecu, ecu harness, intercooler,
boost pipework, intake, airbox, boost controllers, obdII plug
add instrument cluster, key, key reader/ign cylinder, interior harness
the entire car
-. what bits do I need (tranny)
tranny, clutch, flywheel, axles, shifterbox and cables, starter,
7. What other bits and parts can I expect to require later on?
From experience, lots of little things later on. Don't forget all of the bolts and things required to keep everything togeather.
As a side note, the ignition cylinder from a mk3.5 Cabby will fit into a mk1-mk3 ignition cylinder. You CAN use a sidewinder switch blade key.
8. What is your best advice?
wiring manuals for both cars, be prepared to spend alot of time studying the wiring diagrams, don't be afraid to take time off to let your mind rest.
There are alot of 1.8T swaps out there, many are well documented. Reading those will give you plenty of ideas. Realistically, the TDI swap is a little less complicated.
9. Other resources
Hybrid/Swap forum on VWVortex, TDIclub, vwdiesel.net etc.