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Old 28-06-08, 08:08
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aggie aggie is offline
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Default 1.9TDI engine conversion for T4

Hello i just bought a 1995 golf TDI 90 donor car and i am soon to be installing the motor into my T4(currently ABL 1.9TD).Has anyone done this conversion before? Any help and advise will be welcome to help me aviod any unforeseen pitfalls.Thanks!

Turns out im the only one on the forum to have done this conversion then? I wont say it was easy but it was more timeconsuming than difficult!
So who's going to be the next one to convert to 1.9TDI?

Last edited by aggie; 16-02-09 at 21:45. Reason: updated
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  #2  
Old 28-06-08, 08:16
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crftom crftom is offline
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Default Re: 1.9TDI conversion into 1.9TD Help?

not done one myself yet but it should'nt be too bad, i take it you have the full donor car? if so just make sure you label everything when taking the engine out and the same with your van, the engine mounts should be the same/simular its just the engine wiring loom you will need to splice into the van.


tom
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Old 28-06-08, 08:32
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Default Re: 1.9TDI conversion into 1.9TD Help?

http://www.vw-t4.de/index.php?site=tipps&id=1

german guys done it
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Old 29-06-08, 20:31
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Default Re: 1.9TDI conversion into 1.9TD Help?

Thanks! i just read the german thread my girlfriend translated it for me,doesnt give much info but a few little tips. Thinkin that the golf engine leans back and the van engine leans forward i will probably have to swap the sump and oil pick up pipe and possible the oil pump if the pick up pipe is integrated into the pump.The dipstick maybe a problem too as the TDI engine has it at the front and could be hard to get to installed in the T4,maybe i will have to drill the TDI motor at the back of the block and insatll the ABL dipstick and tube.Thinking the clutch and flywheel will have to be swapped over aswell as the T4 clutch diameter is greater than the golf for pulling more weight.Cam cover has a different breather system and oil filler pipe but this will be a straight swap. I plan on swapping all the original ancillaries from the ABL onto the TDI to make installation easier except for the diesel pump and turbo,thinkin of fitting a front mount intercooler from a sharan if i can find one so i dont have to chop the bumper out to get air to the golf one.
Maybe i will be the first to do this conversion in the UK who know's,i will keep you updated with the progress as the saga continues.....
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Old 29-06-08, 20:39
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Big Bad Bear Big Bad Bear is offline
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Default Re: 1.9TDI conversion into 1.9TD Help?

Ever thought of just buying a 2.5 tdi
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Old 29-06-08, 20:50
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Default Re: 1.9TDI conversion into 1.9TD Help?

its a shame your so far away down there in Cornwall i would love to get involved with your conversion , as i said I'm doing the same 1.9tdi myself during the winter when my vans off the road once the summer / show seasons finished .. one thing you might need to look at is the golf pedal box , the golf uses a couple of switches one on the clutch pedal to cut of the power when changing gear also a throttle position sensor on the accelerator pedal .. as far as turbo's go ,i would have to get both turbo's off but I'm sure the 1Z turbo will fit on the ABL exhaust manifold , this would make the oil supply line of thing much easier or even just use the existing ABL turbo as it's only there to produce boost ..
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Old 29-06-08, 20:51
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Default Re: 1.9TDI conversion into 1.9TD Help?

Driven plenty of 2.5TDI's but just dont like the way they rev so slowly,never been a five pot fan unless its a S1 quattro of course! 2.5's are a big heavy lump aswell so im stickin to the four pot variety,reckon i can get around 140 bhp from one and still retain good economy and a quick reving lighter powerplant!
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Old 29-06-08, 20:54
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Default Re: 1.9TDI conversion into 1.9TD Help?

Quote:
Originally Posted by Big Bad Bear View Post
Ever thought of just buying a 2.5 tdi

2.5's i feel are a bit over rated , dont get me wrong they're quick n all but not that quick ... and where's the challenge in just buying a 2.5 much better having something a little different
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Old 30-06-08, 00:09
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Default Re: 1.9TDI conversion into 1.9TD Help?

email the german guy i am sure he will be helpful
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Old 30-06-08, 19:57
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Default Re: 1.9TDI conversion into 1.9TD Help?

Picked the golf TDI up today just after 5pm had it stripped by 8pm engine out loom out and everything else i need. Going to work in the T4 tomorrow so when i have finished working on customers cars im going to strip that out too. need to source a front mount intercooler but not an expensive one,thinking maybe a sharan TDI will do nicely if i can find one locally or on E-bay....
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