TDI Conversions: Build Threads and Links to Swap Discussions

G60ING · Jun 20, 2006

People are always asking for info on swapping TDI motors. I would like to provide a link to the threads where the swaps have been performed or discussed at depth that would give substantial knowledge of what is involved. If you know of links that should be added to this list please let me know, I don’t care where the links are originally posted as my concern making this the most current thread possible for people interested in doing swaps.
The reason that most of us do swaps is because we are passionate about either diesel vehicles or we are passionate about the cars we swap the diesels into. Some are both. If you don't fall into these categories then you really need to research this and think about it to determine if it’s the correct decision for you.
I did mine because I love the hell out of the Corrado and I'm super thrifty. Plus I have a friend who is hardcore TDI and when he drove up to Pa and back without filling up I was super impressed. Then I bought a MK4 TDI Jetta and hated just about everything but the drive train. Soon there after I swapped a mk4 TDI engine into a corrado and sold the mk4 TDI. The rest is history.
Are you really capable of building and maintaining a TDI swapped car? read this: http://forums.tdiclub.com/showthread.php?t=302149
A thread where people talk about their running swaps (they are rarely ever finished):
http://forums.tdiclub.com/showthread.php?t=290656

MK1 Rabbit/Golf/Caddy/Cabriolet/Scirocco Swaps:
Ryan Turner's TDI Caddy Swap using S&P Automotive Swap Kit http://vwdiesel.net/tdicaddy/
MR Dave's ALH into a Mk1: http://forums.vwvortex.com/zerothread?id=778864
charlevoixboy's 1Z 1983 Rabbit GTI: http://forums.tdiclub.com/showthread.php?t=329269
AHU Rabbit: http://forums.tdiclub.com/showthread.php?t=144761
Crazydriver's 1980 Rabbit 1Z/AHU: http://forums.tdiclub.com/showthread.php?t=252931
RabbitGTDJoe's MTDI Rabbit: http://forums.tdiclub.com/showthread.php?t=129127
Lagomorph has many threads related to his AHU TDI swap on the Vortex so I suggest you search his screen name in the mk1 forum: http://forums.vwvortex.com/zerothread?id=1759063
Scirocco ALH Swap: http://forums.tdiclub.com/showthread.php?t=252366
Davidpa28140's Rabbit swap: http://forums.tdiclub.com/showthread.php?t=247517
Top Gear's Project Sipster: http://green.autoblog.com/2009/03/05/top-gear-americas-project-sipster-adds-2003-tdi-engine-to-1981?icid=sphere_blogsmith_inpage_autoblog
WRD's Mk1 02a/02J Brackets (looks like they no longer carry the cable clutch parts): http://wrdusa.com/mm5/merchant.mvc?Screen=CTGY&Store_Code=wrdusa&Category_Code=a1rabbitgtitranny
Caddy AHU Swap Thread: http://forums.tdiclub.com/showthread.php?t=249324
Caddy AHU Pictures: http://picasaweb.google.com/jrcstudios/Volkswagen#
vw_nut's 1Z Caddy: http://forums.tdiclub.com/showthread.php?t=281944
Caddysmack's ALH & Haldex Caddy build (Firewall & frame rail swap): http://forums.vwvortex.com/showthread.php?5901284-TDI-Haldex-Mk1-caddy

MK2/B3/B4/Corrado (they are essentially the same cars with different sheet metal so reviewing all of the threads in this group is wise. Hell reviewing all of the swap threads is even better since there are some interesting tips or tricks in some of the threads that you might want to use.):
Mk2 Pedal Cluster Conversion by FrankenCar: http://forums.vwvortex.com/showthread.php?3247319
Mk4 pedal cluster conversion for a Mk2/b3/b4/Corrado: http://forums.vwvortex.com/showthread.php?2345491
swapping a mk3 and mk4 tdi DBW pedal wiring: http://forums.vwvortex.com/showthread.php?5182138-AHU-DBW-pedal...can-I-use-a-mk4-DBW-pedal-instead
More go pedal discussions: http://forums.tdiclub.com/showthread.php?t=301752
My list of parts for a Mk2/B3/Corrado TDI conversion: http://forums.tdiclub.com/showpost.php?p=2560652&postcount=35
mk2 sound deadening: http://forums.tdiclub.com/showthread.php?t=299926

MK2 Golf/Jetta Swaps:
Frankencar's AHU 1991 GTI: http://forums.tdiclub.com/showthread.php?t=327935
GTiTDi's 91 GTI 8 valve to 1Z: http://forums.tdiclub.com/showthread.php?t=304978
GiGGer's Mk2 PD130 6spd GTI: http://forums.tdiclub.com/showthread.php?t=230282
FrankenCar's 1986 Golf AHU swap: http://forums.vwvortex.com/showthread.php?3247565
Nitrox's Mk2 AHU VNT: http://forums.tdiclub.com/showthread.php?t=275682
borachris's 150pd GTI: http://forums.tdiclub.com/showthread.php?t=296191
CSWTuning's Mk2 ALH Swap: http://www.cwstuning.com/gallery/MK2tdi
AutonUK's: http://forums.tdiclub.com/showthread.php?t=116378&highlight=mk2
pikzibner's 130hp Swap: http://forums.tdiclub.com/showthread.php?t=124004
dubCanuck1's: http://www.canadubs.com/tdiswap1.htm
talk about a mk2 swap: http://forums.vwvortex.com/zerothread?id=2412664
MK2 TDI thread discussion with several Links: http://forums.vwvortex.com/zerothread?id=215913
discussion of a mk2 TDI swap: http://forums.tdiclub.com/showthread.php?t=246154
Bozwell's mk2 Golf AHU TDI swap: http://forums.tdiclub.com/showthread.php?t=251846
Tongboy's Mk2 swap: http://forums.vwvortex.com/zerothread?id=4429958
Shortyclimbs' crazy mk2 build: http://forums.tdiclub.com/showthread.php?t=199314
Fastforward's Golf Country TDI: http://forums.tdiclub.com/showthread.php?t=167583&highlight=Golf+Country
Mk4 Drive by Wire Pedal Cluster Swap for Mk2/Corrado http://forums.vwvortex.com/zerothread?id=2345491
Hendy's Mk2 with MK5 16V TDI Swap: http://forums.tdiclub.com/showthread.php?t=264560
QuantumRallySport's MK2 Golf ALH Rally Car Build: http://forums.tdiclub.com/showthread.php?t=271193
hybrid cluster: mk3 clocks in mk2 cluster housing: http://forums.tdiclub.com/showthread.php?t=303682

Corrado Swaps:
DieselGeek's Corrado TDI FS thread: http://forums.tdiclub.com/showthread.php?p=589058 pictures of Dieselgeek's Swap can be seen on corrado database Here is a picture of the engine bay back from when DieselGeek was selling it
Greasyrides's 1Z Corrado: http://forums.tdiclub.com/showthread.php?t=340586
PRA4WX's 1Z Corrado:

PRA4WX's corrado

PRA4WX's corrado (no boost) I'm not sure why i'm starting this other than maybe a way to keep track of some of my thoughts....... Got this: Pulled this: To replace this: In this:

forums.tdiclub.com

MF Auto Inc. Corrado Race Car with CBEA (common rail 2L): http://forums.vwvortex.com/showthread.php?5731452-MF-Auto-Inc.-Corrado-Race-Car-with-2L-TDI-Swap
Rollercoasterracer/girdwood's ALH Corrado:

Progress on the Corrado

After years of being in need of paint, I finally bit the bullet after it was hit while in storage. My buddy from Denmark took on the project for me, and is doing all the body work, after he went through everything wiring-wise to get everything working again. I'm going to talk to him tomorrow...

forums.vwvortex.com

Purple Tom's UK Corrado 1Z Swap: http://forums.tdiclub.com/showthread.php?t=287475
n0ftInc's 1Z GT1749VA VNT Build: http://forums.tdiclub.com/showthread.php?t=303523
My mk4 ALH corrado swap: http://forums.vwvortex.com/zerothread?id=2303271
Baja Brewer's AHU Corrado: http://forums.tdiclub.com/showthread.php?t=356894
My Mk3 AHU Corrado TDI Swap: http://forums.vwvortex.com/zerothread?id=3280013
AFN Corrado TDI: http://forums.vwvortex.com/zerothread?id=1105053
Corrado with a PD swap: http://forums.tdiclub.com/showthread.php?t=255563
Corrado Diesel: http://forums.vwvortex.com/zerothread?id=4301790
Corrado TD: http://forums.vwvortex.com/zerothread?id=4462532
Mikkijane's TDI Corrado Build: http://forums.vwvortex.com/zerothread?id=3539286
Canadian VR6 Corrado to Mk3 AHU: http://www.customobsessions.com/modules.php?name=Forums&file=viewtopic&t=17946&postdays=0&postorder=asc&start=210
13mmwrench's mid engine Corrado longitudinal with an ALH run on an AHU wiring and ECU: http://forums.tdiclub.com/showthread.php?t=280711
B3/B4 Passat Swaps:
AKAvant's B3 Variant Syncro AHU Build:

1991 B3 Passat Wagon AHU Syncro Swap

So I’ve started this thread before on a few different forums but after a longer hiatus I’ve begun working on the car again and decided to commit to one thread on this forum only. This decision is based mainly on the depth and quality of the information that this forum provides. I’ll be...

forums.tdiclub.com

Converting a B4 VR6 to a TDI: http://forums.tdiclub.com/showthread.php?t=134020&
queek's Syncro TDI B4 Build: http://forums.tdiclub.com/showthread.php?t=226323
LugNuts VR6 B4 VR6 Passat to TDI swap: http://forums.tdiclub.com/showthread.php?t=154656
Queek's 1995 GLX Syncro 1Z Build: http://forums.tdiclub.com/showthread.php?t=301752
Nothingman's B4V VR6 to B4V TDI: http://forums.vwvortex.com/showthread.php?5159307

MK3 Golf/Jetta/Cabrio/Vento Swaps:
Fuslit's 1998 GLX (VR6) to AHU conversion: http://forums.tdiclub.com/showthread.php?t=289897
Converting a MK3 VR6 to TDI: http://forums.vwvortex.com/zerothread?id=2602203
Mk3 Golf 2L/VR6 to a TDI: http://forums.vwvortex.com/zerothread?id=4229486&page=1
Lugnuts Cabrio TDI: http://forums.tdiclub.com/showthread.php?t=249433
VWMikel's 150PD swap into a Golf: http://forums.tdiclub.com/showthread.php?t=164162
Mk3 Cabrio Conversion: http://forums.tdiclub.com/showthread.php?t=269006
Mk3 GTI VR6 to AHU: http://forums.vwvortex.com/zerothread?id=4393478

MK4/Mk5: It has been discussed why a person would want to swap/build their diesel car. Sometimes it’s for the bolt on items like brakes, seats, or what not. Unless you are getting the diesel engine swap dirt cheap then it’s just not worth the hassle of the labor and mixing and matching parts together. Even if you get the engine dirt cheap maybe it’s better to just sell the diesel engine and swap parts and sell your gas car while working and putting the proceeds to the purchase of the diesel car you want. The labor to swap is more than most realize. The oh btw items is always greater then realized. My suggestion is to either get a gasser with a bad drive train DIRT cheap and then get the TDI swap DIRT cheap if you dead set on doing this. That way if you tire of the swap before completion you can always part it out. My suggestion would be to put the money towards gas purchases but then again I have done three swaps and I'm always dreaming up my next swaps(my wife hates this).
eddieleephd's MK4 1.8T Jetta Wagon to TDI Swap: http://forums.tdiclub.com/showthread.php?p=5432144
Mk4 2L gasser wagon to TDI: http://forums.tdiclub.com/showthread.php?t=143981
2000 Golf gasser to a 130PD TDI: http://forums.tdiclub.com/showthread.php?t=248621
1999 Jetta 2L to TDI with a 2003 TDI Golf donor: http://forums.tdiclub.com/showthread.php?t=255936
CharlieT's PD100 AudiTT Quattro: http://forums.tdiclub.com/showthread.php?t=318071
danielhf's R32 (AWD) PD: http://forums.tdiclub.com/showthread.php?p=4017642
greentdiconvertible's 2004 Beetle Convertible BEW: http://forums.tdiclub.com/showthread.php?t=386187

MK5 Swaps:
Jagerauto's Mk5 GTD Swap: http://forums.tdiclub.com/showthread.php?t=470610
b6/b5/mk5 swap discussion http://forums.tdiclub.com/showthread.php?t=233417
Discussion of a Mk5/mk5 Jetta TDI swap: http://forums.tdiclub.com/showthread.php?t=255459

B5/B5.5:
AWD TDI swap discussion: http://forums.tdiclub.com/showthread.php?t=251694
My B5 ALH discussion: http://forums.tdiclub.com/showthread.php?t=281865
SVTWEB's B5 V6 TDI AWD:
Kick off: http://forums.tdiclub.com/showthread.php?t=69668
1/31/2004: http://forums.tdiclub.com/showthread.php?t=70195
4/10/2004: http://forums.tdiclub.com/showthread.php?t=75550
5/28/2004: http://forums.tdiclub.com/showthread.php?t=79496
6/19/2004: http://forums.tdiclub.com/showthread.php?t=80828
Completed: http://forums.tdiclub.com/showthread.php?t=82417
Driving Impressions: http://forums.tdiclub.com/showthread.php?t=98542

Audi Swaps:
DangerBoy's 2.5L AEL C4A6 Avant with VNT: http://forums.tdiclub.com/showthread.php?t=373925
TDIsyncro's 1999 A4 Quattro BHW: http://forums.tdiclub.com/showthread.php?t=212459
Da-BRT's 1977 100 (typ 43) with 2.5 M-TDI AEL: http://forums.tdiclub.com/showthread.php?t=352117
Chirsis 'sAudi Coupe Quattro AFN: http://forums.tdiclub.com/showthread.php?t=368432
Demon Diesel's 2007 A4 BHW: http://forums.tdiclub.com/showthread.php?t=353866
Chaloux's 1996 S6 ALH: http://forums.tdiclub.com/showthread.php?t=304556
CharlieT's Audi TT Quattro PD100: http://forums.tdiclub.com/showthread.php?t=318071
jjordan11's 1988 Audi 80 Quattro to PD130: http://forums.tdiclub.com/showthread.php?t=234380
80 Quattro: http://forums.tdiclub.com/showthread.php?t=253443
tomiisp's Audi 100 PD TDI swap: http://forums.tdiclub.com/showthread.php?t=230954
2000 A4 TDI Swap: http://forums.tdiclub.com/showthread.php?t=254574
TDI Syncro's A4 Quattro BHW Swap: http://forums.tdiclub.com/showthread.php?p=2129132
Audi TT discussion & Swap: http://forums.tdiclub.com/showthread.php?t=177163
Audi TT Swap: Do you have pics? its USA silver TT convertible with a PD TDI
jos br's Audi TT Swap: http://forums.tdiclub.com/showthread.php?t=238054
oil me's '91 Audi 80 quattro M-TDI: http://forums.tdiclub.com/showthread.php?t=344436
Vekke's Audi A8 D2 which was 2.5 TDI V6 to 3 cylinder 1.2 TDI: http://forums.tdiclub.com/showthread.php?t=412491

VW Van swaps:
AndyBee's 1984 Vanagon ALH Build: http://forums.tdiclub.com/showthread.php?t=276798
Markd89's AHU 1978 Bus Build: http://forums.tdiclub.com/showthread.php?t=308793
jjordan11's Father & Son '82 Vanagon Westfalia AHU: http://forums.tdiclub.com/showthread.php?t=279543
Eurovan Discussion: http://forums.tdiclub.com/showthread.php?t=290953
Eurovan Discussion: http://forums.tdiclub.com/showthread.php?t=267136
Aircooled Discussion: http://forums.tdiclub.com/showthread.php?t=229950
1987 Syncro Vanagon: http://www.haywood-sullivan.com/vanagon/TDI/
Fast_Forward's1986 syncro westfarlia http://forums.tdiclub.com/showthread.php?t=133509
PDXpaulie's 1972 Westy ALH: http://forums.tdiclub.com/showthread.php?t=173751
Vanagon Info: http://forums.tdiclub.com/showthread.php?t=202964
Discussion: http://www.cs.yale.edu/homes/jag/vw/engine/tdiswap/tdiswap.html
EuroSpec Sport's conversion Kits: http://www.eurospecsport.com/products/Vanagon/Vanagon%20Page.html
Samba TDI Vanagon Topic: http://www.thesamba.com/vw/forum/viewtopic.php?t=364149&postdays=0&postorder=asc&start=0&sid=89373d1f6ef2151735a2a7568f7042e6
Overview of several swaps and info: http://www.relitech.com/convert.htm
Kennedy adaptors: http://www.kennedyeng.com/
TDI AHU to 93 Eurovan http://forums.tdiclub.com/showthread.php?t=443865
TDI 1Z to 93 Eurovan (budget build) http://[/COLOR]http://forums.tdiclub.com/showthread.php?t=481645http://forums.tdiclub.com/showthread.php?t=481645
AHU swap into 93 Eurovan Weekender

AHU swap into 93 Eurovan Weekender

This is my first post so I decided to jump in head first. I have a road trip through America planned for next May and I want to do it in my Eurovan but I don’t want to pay gas for a 17 MPG vehicle so my solution is to transplant an AHU into my Eurovan. I haven’t found any super detailed...

forums.tdiclub.com

TDI into a '93 Eurovan http://forums.tdiclub.com/showthread.php?t=447952
99 Eurovan T4 TDI conversion http://forums.tdiclub.com/showthread.php?t=308384

Toyota Truck Swaps:

Braddman’s 2005 2nd gen Toyota Tacoma BHW swap: https://forums.tdiclub.com/index.php?threads/2nd-gen-tacoma-bhw-swap.516662/
JayinSpaceman's 1983 AHU MTDI: http://forums.tdiclub.com/showthread.php?t=358097
Alphawerks's Tacoma V6 extended cab ALH: http://forums.tdiclub.com/showthread.php?t=369730
dh13's 1983 AHU MTDI: http://forums.tdiclub.com/showthread.php?t=338519
Danielg42 1988 4runner ALH: http://forums.tdiclub.com/showthread.php?t=316905
ToyotaTDI's 1988 4runder 1Z: http://forums.tdiclub.com/showthread.php?t=317802
FredS's 1994 ALH: http://forums.tdiclub.com/showthread.php?t=344927
dustystdi's1993 toyota sr5 ALH Swap (3 week project): http://forums.tdiclub.com/showthread.php?t=329625
cumminsfromthecold: 1984 Toyota Truck 1Z Swap: http://forums.tdiclub.com/showthread.php?t=304345
jimbote's Tacoma ALH swap: http://forums.tdiclub.com/showthread.php?t=293577[/COLOR]
JayTee013's ALH GT2255 MTDI Build: http://forums.tdiclub.com/showthread.php?t=307050
Eclipse's AHU TDI Truck: http://forums.tdiclub.com/showthread.php?t=176999&highlight=toyota
Spulen81's forerunner: http://forums.tdiclub.com/showthread.php?t=158587
410onefour's AZZ Truck Swap: http://forums.tdiclub.com/showthread.php?t=226334
ALH Toyolta Truck: http://www.pirate4x4.com/forum/showthread.php?t=814008
RWD Transmission Adaptor: http://www.acmeadapters.com/
LukeWilson's 22RE to AHU swap: http://forums.tdiclub.com/showthread.php?t=292227
Toyota Integra TDI: http://projectlocker.ca/ http://forums.tdiclub.com/showthread.php?t=313973
ToyotaTDI's 1st Gen 4runner with AHU: http://forums.tdiclub.com/showthread.php?t=317802

Jeeps:
N2TOH's TDI into Jeep Swappers links: http://forums.tdiclub.com/showthread.php?t=350699
akafred's 1997 Jeep TJ ALH: http://forums.tdiclub.com/showthread.php?t=350396
TDIJ's AHU in a 93 Jeep Wrangler YJ:

TDI YJ Build

Basic build direction for what was later dubbed "BOBCAT": No lift diesel YJ on 35's built for the rocks Where I am now: -Ford 8.8 with auburn -Dana 30 with lock right -4.56 gears and 35's -Boat sides -High lined front and rear -4" or more of lift Current build plans are really quite...

www.pirate4x4.com

68 Camaro Alh conversion

Hey guys, I wanted to start by saying this is my first forum I have joined and I'm a newbie. :cool: The purpose of this conversion - The stock 68 Camaro had a Chevy small block with about 7 mpg and 300 horse. I'm looking to achieve the horsepower with a VW Alh engine and get 35+ mpg. It will...

forums.tdiclub.com

couttsdesign's 1975 bmw 2002 ALH swap: http://forums.tdiclub.com/showthread.php?t=359959

RWD VW discussions:
VWAG to T5 Bell housing

VWAG to T5 Bellhousing

I know this has been mentioned many times, but I am not sure anyone has b been absolutely clear that this bellhousing has been available for a few months now from Quick Time/Lakewood. Endless thanks to vw16Cabby over there. from motorgeek...

forums.tdiclub.com

MrDave · Jun 21, 2006

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:
Questions:

-. 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)
http://www.album.ee/?o=300002220
http://www.cwstuning.com/gallery/MK2tdi

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)
http://forums.vwvortex.com/zerothread?id=1105053
http://forums.vwvortex.com/zerothread?id=389574
http://forums.tdiclub.com/showflat.php?Cat=&Number=590006&page=&view=&sb=5&o=&fpart=1&vc=1
http://www.corrado-tdi.tk

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.

3h. Vanagon
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.

For swaps:
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

IMMO car:
add instrument cluster, key, key reader/ign cylinder, interior harness

best suggestion:
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.

-Dave

bhtooefr · Jun 21, 2006

You want to add it to the wiki?

http://communityhosting.net/tdiclub

highlader69 · Aug 20, 2009

G60ING said:
People are always asking for info on swapping TDI motors. I would like to provide a link to the threads where the swaps have been performed or discussed at depth that would give substanial knowledge of what is involved. Please post the links as you come aross them (it does not matter if they are vortex, tdi club links or links to boards in different countries)

MK1 Rabbit/Golf/Caddy/Cabriolet/Scirocco Swaps:
MR Dave's ALH into a Mk1: http://forums.vwvortex.com/zerothread?id=778864
http://forums.vwvortex.com/zerothread?id=2058015
http://forums.vwvortex.com/zerothread?id=1305859
Lagomorph has many threads related to his AHU TDI swap on the Vortex so I suggest you search his screen name in the mk1 forum: http://forums.vwvortex.com/zerothread?id=1759063
Scirocco ALH Swap: http://forums.tdiclub.com/showthread.php?t=252366
Davidpa28140's Rabbit swap: http://forums.tdiclub.com/showthread.php?t=247517
Mk1 02a/02J Cable Clutch Conversion: http://wrdusa.com/mm5/merchant.mvc?Screen=PROD&Store_Code=wrdusa&Product_Code=010A190&Category_Code=a1rabbitgtitranny

MK2/B3/B4/Corrado (they are essentially the same cars with different sheet metal if enought B3 and corrado threads appear then I'll break them out):
Mk4 pedal cluster conversion for a Mk2/b3/b4/Corrado: http://forums.vwvortex.com/zeropost?cmd=tshow&id=2345491
My list of parts for a Mk2/B3/Corrado TDI conversion: http://forums.tdiclub.com/showpost.php?p=2560652&postcount=35

MK2 Golf/Jetta Swaps:
CSWTuning's Mk2 ALH Swap: http://www.cwstuning.com/gallery/MK2tdi
AutonUK's: http://forums.tdiclub.com/showthread.php?t=116378&highlight=mk2
http://forums.tdiclub.com/showthread.php?t=124004
dubCanuck1's: http://www.canadubs.com/tdiswap1.htm
talk about a mk2 swap: http://forums.vwvortex.com/zerothread?id=2412664
MK2 TDI thread disccussion with several Links:http://forums.vwvortex.com/zerothread?id=215913
discussion of a mk2 TDI swap: http://forums.tdiclub.com/showthread.php?t=246154
Bozwell's mk2 Golf AHU TDI swap: http://forums.tdiclub.com/showthread.php?t=251846
Tongboy's Mk2 swap: http://forums.vwvortex.com/zerothread?id=4429958
Shortyclimbs' crazy mk2 build: http://forums.tdiclub.com/showthread.php?t=199314
Fastforward's Golf Country TDI: http://forums.tdiclub.com/showthread.php?t=167583&highlight=Golf+Country

Corrado Swaps:
DieselGeek's Corrado TDI FS thread: http://forums.tdiclub.com/showthread.php?p=589058 Aditional pics can be seen on http://www.corrado-database.nl/
My mk4 ALH corrado swap: http://forums.vwvortex.com/zerothread?id=2303271
My Mk3 AHU Corrado TDI Swap: http://forums.vwvortex.com/zerothread?id=3280013
AFN Corrado TDI: http://forums.vwvortex.com/zerothread?id=1105053
Corrado with a PD swap: http://forums.tdiclub.com/showthread.php?t=255563
Corrado Diesel: http://forums.vwvortex.com/zerothread?id=4301790
Corrado TD: http://forums.vwvortex.com/zerothread?id=4462532
Mikkijane's TDI Corrado Build: http://forums.vwvortex.com/zerothread?id=3539286
Canadian VR6 Corrado to Mk3 AHU: http://www.customobsessions.com/modules.php?name=Forums&file=viewtopic&t=17946&postdays=0&postorder=asc&start=210

B3/B4 Passat Swaps:
Converting a B4 VR6 to a TDI: http://forums.tdiclub.com/showthread.php?t=134020&
Syncro TDI B4 Build: http://forums.tdiclub.com/showthread.php?t=226323
LugNuts VR6 B4 VR6 Passt to TDI swap: http://forums.tdiclub.com/showthread.php?t=154656

MK3 Golf/Jetta/Cabrio/Vento Swaps:
Converting a MK3 VR6 to TDI: http://forums.vwvortex.com/zerothread?id=2602203
Mk3 Golf 2L/VR6 to a TDI: http://forums.vwvortex.com/zerothread?id=4229486&page=1
Cabrio TDI: http://forums.tdiclub.com/showthread.php?t=249433
VWMikel's 150PD swap into a Golf: http://forums.tdiclub.com/showthread.php?t=164162

MK4/Mk5: It has often ben discussed about why you want to build it when you can just buy it most of the times and bolt on the brakes, awd, interiors and other body parts.
Mk4 2L gasser wagen to TDI: http://forums.tdiclub.com/showthread.php?t=143981
2000 Golf gasser to a 130PD TDI: http://forums.tdiclub.com/showthread.php?t=248621

MK5 Swaps:
b6/b5/mk5 swap discussion http://forums.tdiclub.com/showthread.php?t=233417
Discussion of a Mk5/mk5 Jetta TDI swap: http://forums.tdiclub.com/showthread.php?t=255459

B5/B5.5:
AWD TDI swap discussion: http://forums.tdiclub.com/showthread.php?t=251694

SVTWEB's B5 V6 TDI AWD:
Kick off: http://forums.tdiclub.com/showthread.php?t=69668
1/31/2004: http://forums.tdiclub.com/showthread.php?t=70195
4/10/2004: http://forums.tdiclub.com/showthread.php?t=75550
5/28/2004: http://forums.tdiclub.com/showthread.php?t=79496
6/19/2004: http://forums.tdiclub.com/showthread.php?t=80828
Completed: http://forums.tdiclub.com/showthread.php?t=82417
Driving Impressions: http://forums.tdiclub.com/showthread.php?t=98542

Toyota Truck Swaps:
Eclipse's AHU TDI Truck: http://forums.tdiclub.com/showthread.php?t=176999&highlight=toyota
Spulen81's forerunner: http://forums.tdiclub.com/showthread.php?t=158587
410onefour's AZZ Trauck Swap: http://forums.tdiclub.com/showthread.php?t=226334
RWD Transmission Adaptor: http://www.acmeadapters.com/

Audi Swaps:
80 Quattro: http://forums.tdiclub.com/showthread.php?t=253443
Audi 100 PD TDI swap: http://forums.tdiclub.com/showthread.php?t=230954
2000 A4 TDI Swap: http://forums.tdiclub.com/showthread.php?t=254574
Audi TT discussion & Swap: http://forums.tdiclub.com/showthread.php?t=177163
Audi TT Swap: Do you have pics? its USA silver TT convertible with a PD TDI

VW Van swaps:
Aircooled Discussion: http://forums.tdiclub.com/showthread.php?t=229950
1987 Syncro Vanagon: http://www.haywood-sullivan.com/vanagon/TDI/
Fast_Forward's1986 syncro westfarlia http://forums.tdiclub.com/showthread.php?t=133509
1972 Microbus: http://forums.tdiclub.com/showthread.php?t=173751
Vanagon Info: http://forums.tdiclub.com/showthread.php?t=202964

Others:
Westfield (open wheel car) TDI Build: http://forums.tdiclub.com/showthread.php?t=247471
Samuri TD Build Thread: http://forums.tdiclub.com/showthread.php?t=214676
Saturn: http://forums.tdiclub.com/showthread.php?t=193909&highlight=saturn
Miata TDI Discussion: http://forums.tdiclub.com/showthread.php?t=224534&highlight=miata+TDI
Honda Insight: http://forums.tdiclub.com/showthread.php?t=253045
Town & Country Mini Van Discussion: http://forums.tdiclub.com/showthread.php?t=210943
1966 Volvo 122S Swap: http://forums.tdiclub.com/showthread.php?t=210943
Frontier truck discussion: http://forums.tdiclub.com/showthread.php?t=248621
RX7: http://forums.tdiclub.com/showthread.php?t=204235
Porsche 911 Discussion: http://forums.tdiclub.com/showthread.php?t=168443
Jeep Wrangler: http://forums.tdiclub.com/showthread.php?t=214202
Jeep Discussion: http://forums.tdiclub.com/showthread.php?t=171299

Legality of the gas to diesel swap:
http://forums.tdiclub.com/showthread.php?t=134167
http://forums.tdiclub.com/showthread.php?t=210359
http://forums.tdiclub.com/showthread.php?t=228032
my NC Diesel title conversion experiance: http://forums.tdiclub.com/showthread.php?t=217563

Motor Mounts:
Mk2/Mk3 VNT Rear mounting Bracket: http://forums.tdiclub.com/showthread.php?t=231158
MK3/MK4 Motor mount issues: http://forums.tdiclub.com/showthread.php?t=128485
Mk1 02A/02J WRD Motor Mount Brackets $300: http://wrdusa.com/mm5/merchant.mvc?Screen=PROD&Store_Code=wrdusa&Product_Code=010A180&Category_Code=a1rabbitgtitranny

Flanges and Other Misc Parts that are Useful:
MK4 Map Sensor Flange: http://store.42draftdesigns.com/CNC-Machined-Products_c_6.html
Mk3 Air Temp Sensor Bung: http://www.bahnbrenner.com/vw_audi/products/628/G60_CO_Pot_Sensor_Bung
Mandrel Bends & Pipe: http://www.mandrel-bends.com/catalog/
IC Pipe Metal Transitions Turbo Outlet Size to IC Pipe Size: http://www.verociousmotorsports.com/Shop-by-Category/Stainless-Steel-Reducers/304L-Stainless-Steel-Exhaust-Collector-Reducer

Cruise Control:
http://forums.tdiclub.com/showthread.php?t=253443
http://forums.tdiclub.com/showthread.php?t=193855
Cruise Control & Fuel gauge Info: http://forums.tdiclub.com/showthread.php?t=238766

Immobilizer issues:
http://forums.tdiclub.com/showthread.php?t=136409

RWD VW discussions:
http://forums.tdiclub.com/showthread.php?t=163882
http://forums.tdiclub.com/showthread.php?t=236999
RWD Transmission Adaptor: http://www.acmeadapters.com/

AWD discussions:
TDI into and R32/TT discussion: http://forums.tdiclub.com/showthread.php?t=200111

Pinouts & Wiring Diagrams
Mk4 1999.5 Wiring Diagrams: http://forums.tdiclub.com/showpost.php?p=2305740&postcount=6
Mk3 & B4 Wiring Diagramss: http://forums.tdiclub.com/showpost.php?p=2313317&postcount=19
Pinout discussion: http://forums.tdiclub.com/showthread.php?t=227196
ALH Pinouts: http://forums.tdiclub.com/showthread.php?t=238766

Brilliant!!!!!!! thanks for taking the time to do this.

Makes my learning curve alot easier.

Cheers,

Craig.

Lug_Nut · Aug 20, 2009

Was it really necessary to requote the entire post so soon in the thread?

phazersonstun · Aug 21, 2009

Hahaha! Further Proof that G60ing is da MAN! Thanks man for all your great support!

jrcstudios · Aug 22, 2009

Pictures of Rabbit Truck

I took tons of pictures... More available upon request..

1982 Rabbit truck with A/C:
http://forums.tdiclub.com/showthread.php?t=249324
http://picasaweb.google.com/jrcstudios/Volkswagen#

--JRC

CFM · Sep 16, 2009

Wow, I'm sure that took a lot of your time...thanks for putting so much work into that!

TDIsyncro · Sep 24, 2009

We should add this link for a TDI Engine Drawing. I think its an AHU, but its got a lot of good dimensional info that can be used for any of the vintages.

http://pics.tdiclub.com/data/500/tdi_engine_cad_drawing_small.pdf

whodom · Oct 3, 2009

Here's a swap that should be added to the list above, TDI into 2002 Ford Ranger:

http://forums.tdiclub.com/showthread.php?t=183868

fuslit · Sep 11, 2010

This is my swap/conversion of tdi into a glx shell, fmic and turbo upgrade (gas -> diesel)

http://forums.tdiclub.com/showthread.php?t=289897

cumminsfromthecold · Nov 25, 2010

Re TDI Engine CAD drawing

TDIsyncro said:
We should add this link for a TDI Engine Drawing. I think its an AHU, but its got a lot of good dimensional info that can be used for any of the vintages.

http://pics.tdiclub.com/data/500/tdi_engine_cad_drawing_small.pdf

In the teeny tiny print in the lower right of this sweet CAD drawing, it reads that it's for the AFD engine, for which additional very nice detailed technical data is available, thanks to Mike Sullivan:
http://www.haywood-sullivan.com/vanagon/TDI/tdi-technik-eng.pdf
is just one such gem.

His site here:
http://www.haywood-sullivan.com/vanagon/TDI/
provides even more detailed info on his Vanagon TDI swap.

I asked the same q elsewhere, but I'll ask it again here. How transferable is the info on the AFD to the AHU or ALH?

Thanks

G60ING · Dec 13, 2010

post your links and I'll add them as time permits. I want this thread to remain current but I need your help. Please make certain your swap has details and some progression from the concept stage before posting.

Tdi Kick · Jan 1, 2011

Helpful Threads

Might add these to the list:

http://forums.tdiclub.com/showthread.php?t=295013

http://forums.tdiclub.com/showthread.php?t=290656

Cheers!

Rockwell · Jan 3, 2011

Tdi Kick said:
Might add these to the list:

http://forums.tdiclub.com/showthread.php?t=295013

http://forums.tdiclub.com/showthread.php?t=290656

Cheers!

look at the date/time you made your post

cumminsfromthecold · Jan 10, 2011

aaz_1z_ahu/1z_ahu_diesel_tdi_servicing.pdf

edit
link now dead

Houpty GT · Jan 11, 2011

I found this incomplete photographic swap for a Corrado. Should be nice if he completes it.
http://picasaweb.google.com/mstanbro/CorradoTDIBuild#

My old thread on swapping into a 944:
http://forums.tdiclub.com/showthread.php?t=248485&highlight=porsche

cumminsfromthecold · Jan 24, 2011

'97 Passat Manual

http://thepiratebay.org/torrent/3512555/Volkswagen_Passat_Official_Factory_Repair_Manual_1995-1997.pdf

Conan · Jan 26, 2011

Not sure where to post this, hope somebody sees it here. I'm tossing around ideas for a project, and have begun to research some hosts and donors. I've found an old '80s Honda CRX in good shape with a questionable motor. Thinking of maybe an older (1Z?) swap into that for incredible FE, with great handling, etc. Also spotted a couple of Toyota MR2s that caught my attention. That would be a more expensive, higher tech car, so I'm thinking of a built ALH in that car (200WHP).

Before I go and do something stupid, I need all the info I can get. One hurdle I see is possibly having a hard time registering it and/ or getting emissions test. The title will have the have the host VIN on it, so do you just register it as a '87 CRX? (For example.) I'm in Colorado. We also have different rules for gassers/diesels as far as emissions testing. I'm sure if they see an old CRX that belches black smoke, and sounds like a semi, things will not go well.

Any swappers on here from Colorado?

GTiTDi · Feb 4, 2011

Its been done before but here is my A2 GTI swap http://forums.tdiclub.com/showthread.php?t=304978

cumminsfromthecold · Feb 10, 2011

Fuse Box + Relays + Harness Details, B4 Passat and older VWs

This link appears invaluable:

http://www.a2resource.com/electrical/CE2.html
"This link covers 89-99 Golf and Jetta, 90-97 Passat, all Cabrios, Corrados, and EuroVans."

Double check your information (always). Peruse the rest of the site - there's a lot of great additional info available.

GTiTDi · Feb 12, 2011

cumminsfromthecold said:
This link appears invaluable:

http://www.a2resource.com/electrical/CE2.html
"This link covers 89-99 Golf and Jetta, 90-97 Passat, all Cabrios, Corrados, and EuroVans."

Double check your information (always). Peruse the rest of the site - there's a lot of great additional info available.

Guess I should have just posted this up here before, glad I could help

GTiTDi · Feb 18, 2011

cumminsfromthecold said:
http://thepiratebay.org/torrent/3512555/Volkswagen_Passat_Official_Factory_Repair_Manual_1995-1997.pdf

this doesn't seem to lead to anything promising

cumminsfromthecold · Feb 21, 2011

Passat Online Manual

GTiTDi said:
this doesn't seem to lead to anything promising

http://thepiratebay.org/torrent/3512555/Volkswagen_Passat_Official_Factory_Repair_Manual_1995-1997.pdf

GTiTDi,
Hmmm, not sure why it's not working for you. Look within this URL/page and you will find it. It downloads and opens fine for me (with Firefox), and I now have a complete factory manual! 94,752kb and 4300 pages large.

I wonder if anyone else has found this link useless. Whatever - I dig the info exchange. If you want a copy, send me something to put it on and I will send it to you.

justinoconnor · Apr 3, 2011

Hey,

I'm interested in converting my 1995 Golf III 2.0 from gas to diesel using as many parts as possible from a 1996 Passat glx 1.9L TDI. (I know a Jetta TDI would be easier, but they're hard to come by on a budget)

Does anyone know how much is interchangeable from the Passat TDI to my Golf - but, more specifically, what isn't interchangeable?! ...What would I have to purchase in addition to what I already have between the 2 vehicles to build myself a complete Golf TDI?

Thanks for any response - much appreciated!

G60ING · Apr 3, 2011

Lets run down the list of the parts:
Use B4:
Engine
transmission
shifter
wiring can stay B4 but its not as good of a fit. It gets tricky when you start mixing and matching wiring, ECUs, injectors from early b4s to later mk3s as there were different glowplug wiring and different injector pop pressures.
downpipe

Mk3:
axles
use your mk3 2L a/c hoses and hvac system
intercooler and plumbing (probably easyer to use mk3)
pedal cluster
instrument cluster
airbox
fuel tank and sending unit
radiator (stay 2L gas)

justinoconnor · Apr 3, 2011

Thanks! ...I wasn't so sure that B4's and mk3's were that universal, but sweet!

I originally bought a '97 GTI 2.0 for $200, but the body's in such bad shape that it's unusable - so, I bought the '95 Golf from a friend - it's got a bad transmission and clutch, but a great body - so I was gonna swap the tranny from the GTI to the Golf, then buy a new clutch pack and be done with it - but, then I found a '96 Jetta Trek Edition for $200 with a newer clutch, and spotless front and back sports seats - so I bought it...was/am about to swap everything over, but now I found a '96 Passat glx TDI, and the guys willing to sell it to me for $500 - so that's very tempting, Lol...The engine and transmission are fine, cars only got 120,000 miles on it, new turbo and clutch with about 8,000 miles on um, and a new set of snow tires...the cars got a rebuilt title, and the body's too rough to register it as is - that's why it's so cheap.

Damn, I want it - neighbors are getting pissed though, with the current 3 VW's, and I've got 2 Ford Focus' - one I flipped off the highway this winter, and the other was a parts car for the 1st, haha

G60ING · Apr 3, 2011

Put the foci, GTI, trek's aba engine, and passat shell on craigslist and clear out some room out in the driveway and put a few dollars into your pocket for pedal cluster and instrument cluster.

You really might want to see if you can get a mk3 tdi engine and front clip wiring harness, ECU and injectors. It really will make your swap easier and much more factory like.

justinoconnor · Apr 3, 2011

Yeah, I'm in the process of offing it all, Lol

I'll keep on the lookout for mk3 spec TDI bits, but it all seems pretty costly.

G60ING · Apr 3, 2011

The money spent is well worth it from a frustration point of view. In my mind you would have to spend $300-$500 for all of the mk3 parts. The frustration adverted and the look of the final product is well worth it.

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