Looking to swap MK4 engine into MK2 Jetta - Troubleshooting - VWDiesel.net The IDI, TDI, and mTDI source.

• Looking to swap MK4 engine into MK2 Jetta by jtanguay on 22 Jan, 2007 10:00
• How hard is it to do the swap??? i take it that the engine mounts won't line up...  i did some searching but could only find relevant info on how to convert the pump to TDI  :twisted:
• #1 by burn_your_money on 22 Jan, 2007 10:34
• Motor mounts are pretty much your only hurdle, unless the tranny bolt pattern changed.
  You are going TDIm right?
• #2 by jtanguay on 22 Jan, 2007 10:47
• Quote from: burn_your_money

  Motor mounts are pretty much your only hurdle, unless the tranny bolt pattern changed.
  You are going TDIm right?

  
  
  yep TDI-M
  
  i'm just trying to price everything out... and compare it to getting my 1.6 rebuilt.  if i do go TDI i will probably rebuild my 1.6, or just sell it as a good running motor.
  
  how hard is it to fab up motor mounts to make it work? can i use the transmission out of a mk2 or mk3? will it bolt up???
  
  the motor comes with everything under the hood... might be able to talk myself into getting the intercooler too...  
  
  if its too much work i'll just junk the idea and continue with the 1.6
  
  thanks for the help!
• #3 by SMOKEYDUB on 22 Jan, 2007 13:29
• i think you would only have problems with the trans mount.
• #4 by jtanguay on 22 Jan, 2007 13:46
• hillfolk'r said that there would be some mount problems with the mk4 type engines...  if it was only the trans, and my mk3 trans fits the mk4 tdi... then i'd probably buy the engine.
  
  the engine came from a wrecked 01 jetta tdi with front end damage.  anything i should check for visually?  they warranty the motor for 90 days... problem being i'd like to buy it and install it right away... but winter likes to put a halt on that because working with cold metal just sucks!
  
  one nice thing about this setup is that it comes with the VNT turbo... but i will need to fab something up to get it working mechanically.   probably use a system like Tin Tin.
• #5 by SMOKEYDUB on 22 Jan, 2007 13:50
• is it hard enough were anything was forced right into the engine itself? i.e rad,frame rail.... check for broken tabs or ears on the block..
• #6 by jtanguay on 22 Jan, 2007 16:31
• thats the problem too... i wish the guy had pics of the motor...  maybe i'll phone him up and talk over the phone.  i definitely do not want to drive to London just to find out that some key component is broken off... especially the oil filter housing that sticks out  :shock: they go for around $150 on EBAY!!!
  
  so far building a super reliable solid 1.6TD will probably run me up to around $1200 plus headaches of course...  but the power comparison and fuel economy of the TDI engine, not to mention cold starting potential... its mind boggling... what to choose??!!!  i already have a guy willing to pay $400 for a 2001 auto tranny because his is all screwed up!!! nobody will touch those things!
  
  if it was just the issue with the motor mount, how would it be resolved? i wouldn't mind paying $100-200 to get something fabbed up for it... it would be totally worth it.  
  
  what about those guy's running PD engines in their MK1 and MK2's???  can you guys chime in??? help me decide please!
• #7 by jtanguay on 22 Jan, 2007 18:36
• hmm now that i think of it.. what if i just took all the electronics out of the jetta and swapped it into my car?  but i heard that i need parts of the dash for the electronic security lockout...
  
  so ecu wiring harness... which is already probably hacked up lol ...  even though that would be a huge pain, it seems that it would be much easier than trying to make a TDI-M pump...
• #8 by burn_your_money on 22 Jan, 2007 20:18
• If you want a full TDI swap I think you want one pre 96. I think that is when they got the immobilizer added in along with some other fun snags. I also think around 96-97 they changed the motor mount style and all of the mounts will need to be custom fabbed. Your best bet might to be to bite the bullet and drive up and have a good look. Take measurements and see what you think will be needed.
• #9 by dubCanuck1 on 22 Jan, 2007 20:41
• If you're going with a TDI-M and not using the VNT15, you won't have mount issues. Just use the exhaust manifold from a 1.6TD or a 1.9TD along with the turbo setup and you're golden.
  
  For the 02J tranny, if you're getting it, you'll have to go with the hydraulic clutch conversion. If you go with the cable conversion from an 02A/C on the 02J, the reverse light sensor gets in the way of the bracket. If you go with hydraulic, you'll need the pedal cluster, clutch master/slave, firewall bracket, hose, and brake fluid reservoir.
  
  For the 02A or 02J, you can use the 02A/02C transmission console and bracket. I have them running on the 02J that I'm swapping in.
  
  the only other concern is that you'll have to clearance the frame rail just like the VR6 swaps. Look at my sig for more on that. You'll also have to clock the oil cooler and use longer hoses to reach around as the 020/02A front mount interferes with the routing of that.
  
  If you do go with a hydraulic clutch, you can easily go with the cable shift as well. It's not that hard and you can mount it in the stock height. Here's what I did with mine.
  http://www.vwfixx.com/forums/index.php?showtopic=47349&st=225
  
  I wouldn't worry too much if the passenger's rear ear was broken. You won't use the MKIV mounts on an M-TDI. You don't even need to do it on a full as-is TDI swap. Just cutout some of your rear mount. You do want to check to see if the tranny mount snapped as that's where you would mount your 02A/02C console and mount.
  
  Check to see what kind of damage might have been done to the transfer case and CV's.
  
  ...and your 02A will bolt right in there and can even use the cable clutch.
• #10 by jtanguay on 23 Jan, 2007 06:09
• hmmm maybe i should look at getting the whole car then... looks to be a really big job... the car has an automatic transmission though.  that will need to go as i won't have the electronic hookups and will be stuck in 1st gear lol...
  
  um... after looking at dubCanuck1's conversion... i'm definitely not going that route... too many obstacles to overcome for me i'm affraid.  unless i had my own shop in the garage to work on it...
• #11 by dubCanuck1 on 23 Jan, 2007 10:59
• Yeah. It's not a weekend project....although it's not that hard if you do have the whole car. You just trim the MKIV harness so that it's got only what you need, then hook it up so that you have two fuseboxes and relay panels.
  
  If you're looking for no or little fabrication, the m-TDI is the route to go.
• #12 by jtanguay on 24 Jan, 2007 06:52
• so now theres a '99 TDI engine for $1600.  comes with everything but turbo/alt/starter/ps pump.
  
  can i use the alt & ps pump from my mk2 jetta???
  
  thanks
• #13 by andy2 on 24 Jan, 2007 16:12
• Sounds to me like you would be better off finding the 96-98 TDI engine (1Z/AHU) as they will bolt right into your mk2 with alot less issues than the mk4 TDI engine 99-03? (ALH).
• #14 by jtanguay on 24 Jan, 2007 20:42
• Quote from: andy2

  Sounds to me like you would be better off finding the 96-98 TDI engine (1Z/AHU) as they will bolt right into your mk2 with alot less issues than the mk4 TDI engine 99-03? (ALH).

  
  
  aaarrrggg yes you are right... i thought 99 was a cut off year for MK3... well back to the drawing board... might as well just screw it and go for the reliable beast  :lol: