Author Topic: MKIV TDI Engine Swap to MK2 Golf (Read 15278 times)

dubCanuck1 · « **on:** March 27, 2005, 12:37:21 am »

Hi all,

Posted on this before, but it seems to make people squeamish. I'm researching for a MKIV to put into the MK2 I'm currently running.

I've emailed CWS in Sask. but they haven't gotten back to me. Anyone know of someone whose brain I can pick about doing this swap? Particularly, I'm looking to find out if I need a new harness (current...1989).

Anyone?

??

vwmike · « **Reply #1 on:** March 27, 2005, 04:53:17 am »

A new harness? If I were going to attempt this swap, I don't think I would be trying to replace the entire harness. I've heard it is all one peice from front to back. It would be nice if you could get the engine harness and ECU from a non immobilizer car. Otherwise, you need the instrument cluster and such to make it all work. Ideally they should be from the same car as well. They can be recoded, but it isn't easy. I've swapped many engines and 9 times out of 10 it is easier to adapt the engine to the car, not the car to the engine.

I've heard the MK4's (particularly 1.8T's) have a different crankshaft between the auto and stick cars. Can anyone confirm this? I'm not sure if the difference will affect clutch mounting. It would be simple to keep your stock 020 assuming that the clutch will bolt up.

jtanguay · « **Reply #2 on:** March 27, 2005, 07:01:17 am »

your best bet is to try and convert the TDI to mechanical

http://www.autoshoppingcenter.com/VW/VW_completedieselengine.html

expensive engines, but I'm looking at the 1.9 with simple mechanical injection

jtanguay · « **Reply #3 on:** March 27, 2005, 05:08:21 pm »

well my other option is to find a wrecked TDI and grab the motor from it (provided it works) and then do a mechanical conversion

anyone have access or know where any wrecked TDI's are located???
(in ontario)

dubCanuck1 · « **Reply #4 on:** March 30, 2005, 05:55:42 pm »

Thanks guys,

Assuming I do a conversion without replacing the entire harness, is there a "most compatible" MKIV donor that I could use? I'm getting some info from the after market site that jtanguay suggested. For that price, I think I can have a new one crated directly from VW (I'll get back with research on that).

If I have to splice the harness, what am I looking to splice? If I'm doing a mechanical conversion, is that just the clutch/speedo? The boys at CWS did the speedo conversion as well, so I'm assuming they used most of the harness from the beetle they got the donor from.

Thanks for the help guys. Keep it coming if you've got more....

dubCanuck1 · « **Reply #5 on:** March 30, 2005, 06:34:06 pm »

Quote

You need to be careful about those after market engines, particularly the injection pumps. Many are industrial engines and the pumps are not correct for vehicular use, but optimized for stationary, maintained RPM loads.

So if I'm going to be putting in Stage 2 or 3, I'll likely be replacing that anyway, correct? I'm going to grill them on their engines and parts before I fork out the cash.

Any other caviats?

Dr. Diesel · « **Reply #6 on:** March 30, 2005, 08:20:46 pm »

i'd say your best bet if you really want a TDI would be from a late A3 jetta or b4 passat. I'm 99.9% sure they use an 020 tranny (in the jetta), and you don't have to worry about any immobilizers.

dubCanuck1 · « **Reply #7 on:** March 30, 2005, 09:15:42 pm »

Isn't an immobilizer a security feature? What's the technical difficulty with getting around that?

dubCanuck1 · « **Reply #8 on:** March 30, 2005, 09:18:27 pm »

BTW, what are the differences between the 1.9 TDI from a MKIV and a MKIII? HP, Torque, boost?

GoFaster · « **Reply #9 on:** March 31, 2005, 12:44:16 pm »

The accessories on the front of the engine are organized differently.

The engine mounts are in different places. Mk3 engine mounts are in the same places as Mk2. But it's not the end of the world, because Mk4 engine blocks still have the attachment points for installing Mk3-style engine mounts.

Mk4 has variable-geometry turbo, Mk3 has fixed-geometry wastegate-type turbo. If you are going to use mechanical pump, wastegate is easier to make it work right.

If you are going to keep the electronics, Mk3 engine ECU's will happily run without being attached to an instrument cluster, but Mk4 immobilizer ECU's will not work without an instrument cluster (or so I've heard).

mk1vdub · « **Reply #10 on:** March 31, 2005, 03:53:21 pm »

Hey mate, have a look here: click
it was posted by a guy on the 'tex here

has some info on it but you could probably contact him on the vortex for more specific info, I think theres a few on there who have also done the same conversion so may be worth a look

Nb. I realise a lot of the guys on here rather dislike the vwvortex, and I can see why, but there is some quite good, interesting and usefull stuff on there if you're prepared to shift through all the bickering and other crap :lol:

jtanguay · « **Reply #11 on:** March 31, 2005, 04:31:47 pm »

do the mechanical conversion. For that you need to do some serious mods to the pump though. but no more electrical problems to worry about

btw, I am very interested in finding a wrecked TDI. How common are they at junkyards? I expect to pay around 2-4 thousand for a wrecked one (with a decent engine) anyone know of any wrecked tdi's for sale???

MrDave · « **Reply #12 on:** April 04, 2005, 09:49:34 am »

Quote from: "dubCanuck1"

Hi all,

Posted on this before, but it seems to make people squeamish. I'm researching for a MKIV to put into the MK2 I'm currently running.

I've emailed CWS in Sask. but they haven't gotten back to me. Anyone know of someone whose brain I can pick about doing this swap? Particularly, I'm looking to find out if I need a new harness (current...1989).

Anyone???

Here's my conversion, ALH TDI into a Rabbit Pickup:
http://forums.vwvortex.com/zerothread?id=778864

photo

You basically need to wire in the engine/ECU wiring harness.
That will include a little bit of the interior harness (for the cluster).

I also have an ALH TDI engine sitting on my engine stand.
It's for sale if you're interested.

I'm up in Edmonton, btw...

-Dave

dubCanuck1 · « **Reply #13 on:** April 05, 2005, 08:55:07 pm »

What's the difference between the ALH, BEW, etc?

How much? I'm very interested. Does it have a harness to go along with it? If not, do you have an idea what it would cost to get a new/used one?

MrDave · « **Reply #14 on:** April 06, 2005, 10:27:52 am »

Quote from: "dubCanuck1"

What's the difference between the ALH, BEW, etc?

The ALH is pump injection, the advanced version of the old 1.6D.
The BEW uses unit-injectors (PD, Pump-Deuse), where the 'pump' is built into the injector.

The new PD is a much more advanced design.

Check your PM.

-Dave