TDI into a 99 B5?

Inferno

Member
Joined
Sep 16, 2005
Location
WI
TDI
None
Hello all,

I have a 1999 VW Passat 1.8t manual, and was wondering about putting a tdi engine in the car. The engine I think would fit in best would be the tdi with the AHU engine code. Now, the biggest obstable it seems is actually getting the engine as it would have to be imported from Germany. Anyone have any feedback on purchasing an engine from Germany? Places to buy, shipping costs, etc?

In addition I have been trying to figure out what other parts would be needed. My first question is will my manual transmission bolt to a AHU tdi? The gear ratios are close from what I gather, so I think I could get by with it.

Now the part that concerns me the most is the wiring harnesses. Would I be able to get by with just a new ecu and engine wiring harness? ETKA lists different part numbers for the ac harness in the AHU and the AEB(1.8t). What other harnesses are needed? Will I be required to replace all the wiring harness in the car?

Another question I had deals with the fuel tank? Would I have to purchase a tdi fuel tank or can my current tank be modified in some way to work?

Has anyone put a tdi engine in a pre 2005 B5 passat other than SVTWEB?

Thank you for any input.
 

mogly

Veteran Member
Joined
May 27, 2003
Location
Sarnia, ON, Canada
TDI
MKIV TDI + B5.5V AVF/01E
I drove a 130PD 6 spd Passat Variant when I was in Germany two years ago. Nice ride. Excellent conversion should be right easy with a complete donor packaged.
 

ta79pr

Veteran Member
Joined
Sep 18, 2005
Location
Lexington, SC
TDI
02 TTQ (BEW)
I am attempting the same thing, I have an ALH w/ 5speed. The engine mount(s) is my first concern.
 

karlaudi

Veteran Member
Joined
Aug 24, 2005
Location
San Francisco Bay area
TDI
2002 VW Golf GLS 1.9TDi; 2012 Volkswagen Golf 2.0 TDi
I have considered the conversion of my 1.8T to a 110 hp TDi as was offer in the European version of my 2000 (B5) Audi A4 Avant quattro with 5 speed.

There are several sources to consider:

1) Buy a complete donor car from Germany as listed for example on eBay Deutschland.

2) Britain's Volkswagen Driver Magazine did a recent profile on a B5 Passat 1.9 TDi to 2.7T V6 conversion. So, at least someone in Britain has the expertise for such a conversion.

3) Buy a clean 2000 A4 1.9TDi Avant Quattro Sport from Germany, France, or Switzerland and use my car as the donor vehicle to bring it up to Federal and California standards.

4) Of the known German Tuners, I would contact M-T-M [Motoren-Technik-Mayer] as I believe they may be the most suitable and skilled of the "Factory" associated VW / Audi Tuners in Engine Conversion Upgrades.

It is currently just a thought, as I lack the budget at the moment.
 

Inferno

Member
Joined
Sep 16, 2005
Location
WI
TDI
None
ta79pr what problem are you having with the engine mounts, from pictures i have seen the diesel mounts appear identical. I know the v6 and 1.8t mounts are the same except that the v6 mount is a little stiffer.
 

karlaudi

Veteran Member
Joined
Aug 24, 2005
Location
San Francisco Bay area
TDI
2002 VW Golf GLS 1.9TDi; 2012 Volkswagen Golf 2.0 TDi
Ta79pr,

If you have not done so already, may I suggest that you purchase a European ETKA CD-ROM from someone, as I did, on eBay Deutschland. It's easy! Then a US spec ETKA and start comparing part numbers between the various engine codes as US Engine codes are not necessarily listed on the German spec ETKA.

INFERNO is right, the mounts look similar, but mounts and brackets are different among to 4 cylinder gas and diesels, unique for the 5 cylinder, and vary again between the V6's.

As best I can tell, by a quick check, of all the mounting brackets there are two possibilities for the left engine bracket to mount and four for the right. The body to engine mount brackets are the same for all 4 cylinder motors in all German spec.1999 Passats. The front rubber stop varies between Auto and Manual trans as well as motor.

As for the actual mounts, unless you have an ATJ or AVB motor the left hydro mount is:

8D0 199 379 J

And the right for an AHU / AHL motor (and is not the same for a AEB motor) is:

8D0 199 382 M

Then there is the matter of all the other brackets, supports, stop plate(s), nuts and bolts, and other hardware to cross reference for these type of conversions as they can and do vary among all the various engines fitted.


General rule of thumb. If VW / Audi ( or any one for that matter) can use the same part in one of more applications they will. If the part number is different between a 1.8T and a 1.9 TDi or even among the various version of the same motor than there is an engineering reason for it and hence the "production costs" justification for the difference between the various versions.
 
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