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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 December 6th, 2016, 06:39   #16
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I agree with others here - not an AHU, but something from a Audi or Passat from Europe. The issue is going to be the AC compressor is going to be on the wrong side. If you are getting the electronics with it, it will also have an immobilizer because it is a non-north american engine. It would be a decent engine for someone installing into a Ranger or pickup that has the steering rack in the way though.
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Old December 6th, 2016, 15:07   #17
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Well I didn't actually buy it from the auction, I called the number listed in the ebay auction and made the deal on the phone. I'm going to take those pictures down because they are inaccurate and reflect my very limited knowledge of VW still, but I am trying to learn.

I did verify 100% that the engine I purchased was an AHU, but I'm going to wait until it gets here and post my own pictures, just so I can't screw anything else up lol.

As far as it being too expensive I've been trying to find one for probably 4 months now and this was the first one I've found. If you know where to get them, please let me know.
I already have made the deal so the engine, wiring harness and various other parts are already taken care of. So the only two major parts I need now are a transmission (I've done some research and found that a code EGR transmission will work best in my application since I'm using an MK4 shifter, PLEASE correct me if I'm wrong)

I'm still looking for a Saturn to do it with, but that will be my last purchase as I don't really have a lot of room to store all this stuff.

I will keep you guys posted.

Last edited by specialed1995; December 6th, 2016 at 15:13.
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Old December 6th, 2016, 15:40   #18
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What state are you in?
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Old December 6th, 2016, 16:07   #19
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What state are you in?
West Virginia
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Old December 6th, 2016, 17:13   #20
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https://winstonsalem.craigslist.org/cto/5908195974.html

https://roanoke.craigslist.org/cto/5898148646.html

https://danville.craigslist.org/cto/5871953182.html

https://raleigh.craigslist.org/cto/5906545219.html

https://asheville.craigslist.org/pts/5885194352.html

Don't know how close any of these are to you, but they all have the engine you want, along with the ECU, harness, transmission, axles etc. The last one is a part out so you wouldn't have to take the whole car...
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Old December 6th, 2016, 17:17   #21
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Why are you "stuck" on an AHU? These motors are getting quite old and most have mega miles on them now.

You can get complete ALH (2000 to 2003) cars around here for a $2000 Canadian if you do your shopping - this way you have the whole car to play with in case you need parts. The turbo is more modern, the ECU can be flashed over the OBD port, CAN bus for cool things like my CAN2DASH gateway and usually less mileage. I think there is more collective knowledge on the ALH than there is on the older 1Z/AHU engines.

Just my two cents anyhow!
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Old December 6th, 2016, 17:25   #22
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Well I guess you were right yet again lol, but I've already accumulated lots of the parts I'll need and am very limited on room so a whole car wouldn't be practical for me, but I greatly appreciate you for sending me those links.

Now my biggest concern is getting this swap all sorted out and obtaining a transmission. I've heard that an EGR code transmission will work with the AHU and be compatible with my MK4 shifter, can anyone verify this? Other than a new clutch and timing belt what are some other things I should check/do while I have everything apart?
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Old December 6th, 2016, 17:53   #23
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Quote:
Originally Posted by Hasenwerk View Post
Why are you "stuck" on an AHU? These motors are getting quite old and most have mega miles on them now.

You can get complete ALH (2000 to 2003) cars around here for a $2000 Canadian if you do your shopping - this way you have the whole car to play with in case you need parts. The turbo is more modern, the ECU can be flashed over the OBD port, CAN bus for cool things like my CAN2DASH gateway and usually less mileage. I think there is more collective knowledge on the ALH than there is on the older 1Z/AHU engines.

Just my two cents anyhow!
I decided on the AHU because from what I've read the wiring is much simpler, the ECU doesn't have an immobilizer, and it just seemed more basic, which is suited to my style. I'm not saying I'll never try to do it with an ALH, but for right now my choice is the AHU.
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Old December 6th, 2016, 21:14   #24
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I have already contacted a machine shop and have the axle adapters being machined as we speak, and they should arrive with a couple weeks. I'm still trying to figure out how to properly measure the axle length, but of course I can't do that until I have the engine and trans mounted up in the car where it's going to go.

For the engine mounts I plan on following in CFM's footsteps and fabricating the front engine mount and rear trans mount and adding a new crossmember to the engine cradle in order to use the stock VW trans mount bolted to the front by the starter.

This is just another idea but if the engine I get comes with AC I would like to find a way to use the VW AC compressor with the Saturn AC system. I know I would most likely have to get new lines with different fittings and reroute them to make them fit, but if it's possible I'd like to keep the AC, even if I have to rig it up to a toggle switch.

As far as power steering goes I am doing a pump delete and plan on cutting the lines on the power steering rack, running a rubber hose with a "T" fitting to both ends, and run the other end up to a little reservoir (like one for a clutch master cylinder, new of course to avoid contamination) just to keep the rack lubricated. These cars are very light and are not hard to drive with no power steering, so I don't mind losing that.

I am open to any and all suggestions, this is a fun learning experience for me and I'm enjoying every minute of it. Thanks everyone
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Old December 7th, 2016, 10:26   #25
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For the manual steering, you should seek out a rack from a Saturn "SL". It was an entry level model with manual steering. It would simplify your manual steering solution.

For the AC, you will need to fabricate lines, and route them differently, as the AC compressors are in different places in these cars, but the SL's had a variable compressor TXV system, just like the jetta/Passats that the AHU came in, so you should be able to make it work. You would need to marry the Saturn HVAC with the VW ecu, but it should be doable.
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Old December 7th, 2016, 15:14   #26
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I've seen manual steering racks for sale online, but if I can save money and use the rack that's already in the car by just modifying it I'll do that because to be honest I'm pretty cheap lol.

I remember there being a couple wires coming out of the ECU for the AC, but I can't recall right now which ones they were (I have a whole list of all the wiring I've sorted through so far and several wiring diagrams I've found online tho) but I agree there's got to be a way and it shouldn't be too difficult.

I'm still trying to figure out what size square tubing I'll need for the engine cradle crossmember, but I'm sure it doesn't have to be exactly the same as what CFM used in his conversion, as long as its thick enough to hold up to what the engine puts it through it will work.

I'm going to also weld a thicker piece of sheet metal on where the crossmember and sway bar bolt on to reinforce that too. I would guess that 1/8 inch sheet metal would do, probably two 1 foot square pieces which I could cut into the shape they need to be and drill new holes for the crossmember and sway bar. I plan on welding nuts inside them to make bolting everything back together a breeze.

I've also ordered the Energy Suspension Doughnut Bushings that CFM used for motor mounts and will use them as a template to draw up plans and get better measurements for the mount and get everything finalized. Once my engine gets here I'm going to measure the distance between the two bottom bolt holes on the front of the block (to the left of the crank pulley when looking at the engine from the front) and see where the holes in the mounts are going to go, same with the holes in the transmission where the axle drive hub comes out to make that mount. From CFM's pictures they both are designed very similar so the sizes for one should be pretty similar to the other, aside from factoring in clearance issues, which I'm sure I'll figure out once I get the drivetrain sitting in the vehicle.
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Old December 7th, 2016, 15:47   #27
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Good that you're making progress.

Other than the elimination of the hydraulics, the manual rack also has more turns lock-to-lock compared to the power rack, so parking lot effort is less strenuous.

However the power rack should work just fine, just be harder to turn when the car is at low speed.

EDIT - $69 including shipping... http://www.ebay.com/itm/96-97-98-99-...RXyITp&vxp=mtr
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Old December 7th, 2016, 16:48   #28
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Something I haven't quite figured out yet is the wiring for the cooling fan. I plan on using the Saturn fuse box and just adding fuses and relays in as I need them, and I plan on keeping my manual fan switch, which grounds the relay and turns the fan on, but I'm not clear on how the ECU tells the fan to come on. I don't remember reading anything about the cooling fan in the ECU wiring diagram so I hope you guys can help me.

I looked into my wiring diagram and found that ECU Pin 28 is the AC output to the relay and ECU Pin 37 is the AC input from the switch inside, but that's all I could find as far as the ECU goes, I haven't investigated any further than that yet, tho.

Thanks for all the support and encouragement!

Last edited by specialed1995; December 7th, 2016 at 16:56.
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Old December 7th, 2016, 17:01   #29
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With the suggestions of others on here I went with a thermostatic switch.I
wanted to use the OEM controller but it didn't work and I almost overheated
badly.With this switch you can dial the fan to come on within 5 or so degrees
of what you want.

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Old December 7th, 2016, 17:13   #30
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Quote:
Originally Posted by 1.9ZOOK View Post
With the suggestions of others on here I went with a thermostatic switch.I
wanted to use the OEM controller but it didn't work and I almost overheated
badly.With this switch you can dial the fan to come on within 5 or so degrees
of what you want.

Thank you so much!!!
That would a simple solution, which I love!
Do you have a link or a part number for that?

Also does anyone know the temperature at which the fans should kick on?

Last edited by specialed1995; December 7th, 2016 at 17:18.
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