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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 15th, 2009, 12:32   #1
classicgameswi
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Default Corrado PD swap

Well, I finally am making progress on my corrado TDI project.

I am using a BEW motor from an '04, with a cluster from an '01 ALH. all the wiring is spliced into the CE2 fuse panel.

I have 95% of the wiring done, I swapped the heater box in from a MK4,
all new speaker wiring, fixed the power seat belts, bolted in the motor, I have the DBW pedal mounted.

I have a thread on Vortex with more info HERE

there are a few things I am having trouble figuring out:

1. I am using a MK4 cluster with the CE2 wiring, and while it is mostly working, the backlighting does not work, is this handled diferantly on a mk4 than a CE2 car?

2. How do I connect my custom intercooler piping to the turbo outlet on the kp-39 turbo? also, what size pipe would you use? I am using the G60 intercooler.

3. are there any threads covering a heater box swap using a MK4 unit? I have it mounted, but there are a few fitment issues that I would like to see how it has been done.

4. can I just use the fuel pump to empty the gas tank, then refill with diesel, or do I have to drop the tank and empty it 100%.

5. I am using a 1.8t accessory bracket and tensioner because the original was missing, and the tensioner pulley is rubbing on the timing cover just a bit. Is the tensioner diferant, or is the bracket the culprit?

Any suggestions are welcome.

Thanks
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Old August 15th, 2009, 18:46   #2
Lug_Nut
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Quote:
Originally Posted by classicgameswi
4. can I just use the fuel pump to empty the gas tank, then refill with diesel, or do I have to drop the tank and empty it 100%.
Any suggestions are welcome. Thanks
My first swap was between similar models and body style, B4 wagon to B4 wagon. Swapping the tank was no real added effort.
My current one is an A3 Cabrio, no TDI tank to fit in. I drained the gasoline tank using the in-tank fuel pump. I then added about 5 gallons of B100 biodiesel (that's what I have on hand) to dilute the gasoline remaining and pumped that through too.
Then I filled the tank with B100 and left it at that.

The gasoline went into an Audi I was borrowing. The gasoline 'contaminated' biodiesel is being used in my diesel lawn tractor.
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Old August 15th, 2009, 19:48   #3
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That is the method I was thinking of using, as it is how I removed the old gas in the tank when I was trying to get the G60 running.
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Old August 15th, 2009, 21:12   #4
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I started by pumping out all of the gas in my Golf. After that I pulled the in-tank pump out and got the trickles on the bottom using an electric fuel pump and some hose. After that I used some paper towels to try to get every last drop. Then after the pump was back in I did the ventectomy and ripped the restrictor out of the filler. Everything has worked out fine since.
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Old August 16th, 2009, 05:59   #5
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Droppi ng the fuel tank is easy after the fuel is out of it. Use the fuel pump to pump out the gas and then drop it.

Jack car up and put on jack stands
remove the fuel door rubber boot
remove the fuel lines and vent tube
Place a jack with a piece of wood under the tank
remove 10mm bolt from wheelwell
remove fuel tank straps.
Drop tank and remove via the wheelwell.

Its not complicated don't be scared.
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Old August 16th, 2009, 06:02   #6
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Wash the outside of the tank there is bound to be a lot of caked on mud up by the spout. I used compressed air, garden hose and a brush to get it off. This will help prevent the car from rusting near the mud.
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Old August 19th, 2009, 10:30   #7
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Thanks for the info about dropping the tank, In my case, it might be a bit different as there is a hitch installed on the vehicle.

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Old August 19th, 2009, 10:38   #8
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even still get the mud out of the upper part of the wheelwell so your swap won't rust out after its completed
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Old August 19th, 2009, 17:48   #9
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I will do that for sure as I have a rust free shell and I intend to keep it that way :-) After I get the swap done I want to pull the motor and interior and get the car painted. Either that or find an even cleaner shell.
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Old August 19th, 2009, 21:23   #10
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Hi Alex
The manifold has a nipple not a flange
LMK when you get it
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Old August 20th, 2009, 08:54   #11
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Even better! Then I don't have to make an adapter.
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Old August 28th, 2009, 21:40   #12
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Planning a MK4 1.8t conversion to a PD, Can the gas tank and fuel lines be reused?

I assume just swap out the gasser lift pump to a PD lift pump?

tnx


Quote:
Originally Posted by Lug_Nut
My first swap was between similar models and body style, B4 wagon to B4 wagon. Swapping the tank was no real added effort.
My current one is an A3 Cabrio, no TDI tank to fit in. I drained the gasoline tank using the in-tank fuel pump. I then added about 5 gallons of B100 biodiesel (that's what I have on hand) to dilute the gasoline remaining and pumped that through too.
Then I filled the tank with B100 and left it at that.

The gasoline went into an Audi I was borrowing. The gasoline 'contaminated' biodiesel is being used in my diesel lawn tractor.
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Old September 1st, 2009, 20:40   #13
classicgameswi
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should work fine as far as I know.
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Old September 2nd, 2009, 04:32   #14
G60ING
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Quote:
Originally Posted by tothemax
Planning a MK4 1.8t conversion to a PD, Can the gas tank and fuel lines be reused?

I assume just swap out the gasser lift pump to a PD lift pump?

tnx
If you have access to a mk4 diesel tank thenk just use that as it has the correct size nozzel inlet. Better yet why not just sell everything and buy an OEM TDI
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Old May 5th, 2010, 12:19   #15
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Well, After having vwmikel disable the immobilizer on my ecu, i have started the beast! I only had it running for a few seconds because the radiator and interercooler arent connected yet, but it smells and sounds good!
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