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Discussion Starter #1 (Edited)
Good evening guys and girls and anybody who's interested, i've decided to start my build thread to document my engine swap over the coming weeks.

To set the scene i have a p reg 1.9td ABL which has done 117k and is camper converted. I use it daily for work and at every opportunity that im not at work for surfing, camping, cycling and generally enjoying life.



Problem is as many have come across is that the 68bhp ABL in standard trim with the standard engine just isnt up to scratch so set about doing something about that. The first modification i made to make it better for the standard M5 motorway crawl was to fit a fifth gear from a golf gearbox which i found in the local scrappy. The engine had already been attacked by the vultures so wasn't worth purchasing everything at this point.

So i fitted the fifth gear to reduce the engine revs at typical motorway cruising speeds. I've also played around with the boost and fuelling on the abl but found the increased power hampered the economy which isnt the ideal solution to the problem. This only leaves changing the engine to obtain a more efficient means of producing a sensible amount of power that im after.

If not trying to produce a t4 rocket, i just want an economical t4 with a power output in the region of 120-130bhp.

So in late october i purchased a donor vehicle for the conversion. Vw golf estate cl tdi 122k miles FSH (vw up until 109k), mot till Feb for the sum of £450. AHU engine code.





Unfortunately my sisters boyfriend had a terminal engine malfunction in his own car the week after i purchased this, and seeing as i had no plans to use the car in the short term, i put the conversion on hold and lent him the golf. It was a chance to see if there's any problems with the golf, seemed fine on the way home but you can never tell from one journey.


It gave me some time to purchase all the other bits required for the conversion - sprinter intercooler and hoses (cheers mace for the hose info!)



trip to vw for the 2.5tdi pedal and bracket (x2 on both as a mate of mine is also converting his soon too )



Step one was for pience of mind really was to change the cambelt and tensioner on the golf before i lent the car. Took us 90mins to change the belt in -6 degrees (was long enough!!) and checked the timing afterwards with vagcom.

Vagcom also gave a fault code relating to the MAP sensor so may need to get a new one for the conversion.


So theres where i am!,

Im due to get me golf back next week so will be cracking on and removing the engine from the golf over xmas to then prep for a swap in the new year weather permitting.


Got a few issues with the t4 i need to address when doing the swap too,
*My clutch release bearing sounds awful, can only hear it when in neutral and its not in gear, its always been like it but it needs changing. Box is super quiet in gear and under load.
*I think my replacement clocks in the van may be from a 2.5tdi rather than a 1.9td so will need to run a feed to the clocks from the ECU or use the golf clocks.
*My heating is stuck on hot in the van, control unit is fine, cable is fine so must be the heater valve, will inspect when taking the van apart.


I also put in for my Mot early this week so i am in no rush with this conversion. It flew threw except from an advisory i was expecting which is also another reason this engine needs to go. I have a fairly productive oil leak from the abl engine. (cambelt end) camshaft seal maybe? and they advised that it could cause the cambelt to wear prematurely. (Best fit a TDI engine then!!)
Cheers
 

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Good luck with it - you won't be disappointed with the result. And as Jimmy says, you will have the advice of all the tdi people at your disposal T:T:
 

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Looks like your set to go dudeT: The conversion is by far the best thing Ive done to my van !
So much fun to drive now, it should be more economical buy I just cant help myself :D

You'll love itT:

As you are doing the same intercooler piping setup as me, remember you need to keep the plastic bit of pipe with the inlet temp sensor in.
You just need to do a but of trimming at each end to make it fit nice, and a bit of a bend to the dip stick to make it get out the way of the pipe.
Youll also need to cut a bit off the 45mm straight pipe to fit and also a bit off one of the angled reducers, youll see when you come to fit it.

Also shaving the bottom hinge mounts off the radiator with a saw/file as its a bit tight squeezing the IC pipes round the rad.




I used a bit of foam stuck to the back edges of the IC so it didnt rub on the rad.

And with the PS cooler I cut one end, filed the mounting bracket off and used a bit of pipe as a joiner to, 1 lengthen the pipe to clear the rad nicely and 2 so that I can change the angle of the end bit of pipe to face into the engine bay so its out the way of the IC.



But like the other guys say, any probs, just put them up here and someone will be able to help you as they did meT:
I spent most nights after it got too dark/cold to work on the van reading over and over everyone elses conversion threads and all the other info in the tdi library. I found it very useful.

Have fun dude T:
 

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Discussion Starter #5
cheers guys, i'm sure there will be a barrage of questions along the way but i've got a few to get the ball rolling.

1. Will the cruise control stalk people fit to the 2.5tdi t4's work with my AHU engine?

2. Is it really worth getting a decat pipe? will it really make that much difference?

3. Being a 1996 van i guess i must have a fairly early form of immobiliser. I Don't think my keys have transponders or anything. Am i going to be able to get this engine running in my t4 and still keep my original barrel and key so that the vehicle is all off one key still or will i have to use the golf barrel and loom?

4. Ive also got a early 1z tdi ecu that i effectively got for free. Is this of any use to me (i.e can it be used with my immobiliser loom in the t4 if using the ahu ecu in combination with my original key isnt an option?)

5. Can i use the golf coolant expansion tank?

cheers Andy
 

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cheers guys, i'm sure there will be a barrage of questions along the way but i've got a few to get the ball rolling.

1. Will the cruise control stalk people fit to the 2.5tdi t4's work with my AHU engine?
It's the same - so yes.

2. Is it really worth getting a decat pipe? will it really make that much difference?
Depends - because I'm cheap I would just cut open the existing cat and remove the monolith before welding it back up again. Yes it's worth doing. The next cheapest option is to buy a 1.9TD pre-cat downpipe.

3. Being a 1996 van i guess i must have a fairly early form of immobiliser.
Yes I think it will, but it depends on which end of '96 your van was produced

I Don't think my keys have transponders or anything.
Yes they will if the van has an immo

Am i going to be able to get this engine running in my t4 and still keep my original barrel and key so that the vehicle is all off one key still or will i have to use the golf barrel and loom?
Why would you have to change the key/barrel to the golf one :confused:

4. Ive also got a early 1z tdi ecu that i effectively got for free. Is this of any use to me (i.e can it be used with my immobiliser loom in the t4 if using the ahu ecu in combination with my original key isnt an option?)
You are thinking too-hard about this. Take the old immo and all the associated wiring out of the van and throw it away - it is of no use to you for the conversion in any shape or form Forget about the spare ECU.
 

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Take the old immo and all the associated wiring out of the van and throw it away - it is of no use to you for the conversion in any shape or form Forget about the spare ECU.
dont be too hasty in this part - check the immob fitted to the van first ( right hand side of the clocks in both vehicles ) if they are the same unit then the wiring can be used ;)

2 types of immob fitted one is all black and has large plugs the other is black/brown and has small plugs.

you still need to use the golf one but will save you some time pulling a loom out that you already have fitted.

if the older ECU is a 94 ish one then this will probably not have any immob circuit fitted pm me the ecu number and i will check it against the one i have - its worth saving as you can fit it at a later stage to eliminate the immob if you get issues with it T:
 

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Discussion Starter #11
thanks for the replies, good news about the cruise control will get hold of the parts for this and do this at the same time as the conversion.

The V5 says the date of first registration is 3rd September 1996.

In terms of the expansion tank, basically when i purchased the van it had just had a recon head. The coolant system had been flushed through but everything was still coasted with oil.

I ran the hose through the rad, took all the pipes off and cleaned what i could out and scrubbed what i could out of the expansion tank but as its an awkward shape even with an old toothbrush its still grubby, horrible and impossible to see my coolant level, its like the plastic is stained. I have to dip it and measure the level!! The coolant is free from oil now though.

So wanted to know if i could use the golf one as its clean or do i need to buy a new one from vw?
 

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dont be too hasty in this part - check the immob fitted to the van first ( right hand side of the clocks in both vehicles ) if they are the same unit then the wiring can be used ;)
You cannot use any of the older wiring - the reader coil is different and so are the connectors for the immo box regardless of the type of immo box. It is better to start afresh with known quantities rather than bodging your way through and then having to iron out the problems as a result.

if the older ECU is a 94 ish one then this will probably not have any immob circuit fitted pm me the ecu number and i will check it against the one i have - its worth saving as you can fit it at a later stage to eliminate the immob if you get issues with it T:
Incorrect again I'm afraid. The pre MY95 ECU does not have an integrated barometric pressure sensor, so you would have to either bodge the wiring for this or change the harness to an older one - hardly a simple job
 

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thanks for the replies, good news about the cruise control will get hold of the parts for this and do this at the same time as the conversion.

The V5 says the date of first registration is 3rd September 1996.

In terms of the expansion tank, basically when i purchased the van it had just had a recon head. The coolant system had been flushed through but everything was still coasted with oil.

I ran the hose through the rad, took all the pipes off and cleaned what i could out and scrubbed what i could out of the expansion tank but as its an awkward shape even with an old toothbrush its still grubby, horrible and impossible to see my coolant level, its like the plastic is stained. I have to dip it and measure the level!! The coolant is free from oil now though.

So wanted to know if i could use the golf one as its clean or do i need to buy a new one from vw?
Take the tank off, plug the holes and fill with coca-cola. Leave overnight and hey presto - perfectly clean expansion tank!

You can also use denture cleaning tablets - does the same job...or so I've heard :)
 

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Discussion Starter #14
Haha! ill give that a go when i strip the van down in the new year A:

hopefully should be able to start pulling the golf to bits straight after xmas.

I've got a week and a half off so want to make as much progress as possible.

will stick with all the AHU wiring and get the other ECU on the bay.
 

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The problem with the AFN is the turbo. There is no clearance and you will have to use a hammer on the van to make it fit :eek:

João
 

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Any reason for going for the 90 Hp AHU and not the 110 AFN ? or have I got this info wrong !
I don't think UK ever got AFN engined Golf - it is available in other vehicles of course. AFN uses VNT turbo, and also different ECU. It's nicer to drive and offers more progressive throttle response because of the VNT, but you cant use the T4 wastegate turbo and manifold with it unless you modify the bodywork and get a custom downpipe made...
 

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You cannot use any of the older wiring - the reader coil is different and so are the connectors for the immo box regardless of the type of immo box. It is better to start afresh with known quantities rather than bodging your way through and then having to iron out the problems as a result.



Incorrect again I'm afraid. The pre MY95 ECU does not have an integrated barometric pressure sensor, so you would have to either bodge the wiring for this or change the harness to an older one - hardly a simple job
Not wrong on either part - both options have worked on previous conversions.

The immob 2 was fitted to the golf and to some early t4's - as fitted to tidyts 1st conversion so no loom or sender change needed JUST the transponder chip in the key.


The older ecu will run the 1z or AHU with the barometric sensor / loom missing, as it did in mine for several months without any issues. VW & ABT both told me the sensor is virtually redundant in Uk as it only makes any real difference if you are running high altitude such as the alps etc
 

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Not wrong on either part - both options have worked on previous conversions.

The immob 2 was fitted to the golf and to some early t4's - as fitted to tidyts 1st conversion so no loom or sender change needed JUST the transponder chip in the key.


The older ecu will run the 1z or AHU with the barometric sensor / loom missing, as it did in mine for several months without any issues. VW & ABT both told me the sensor is virtually redundant in Uk as it only makes any real difference if you are running high altitude such as the alps etc
For your edification:

There were a variety of immo 2 immo boxes fitted to the IDI engined VW T4 made by: 1) Siemens/VDO 2) Temic, 3)Motometer, and 4)Sagem (in the last few 1.9TD's)

Siemens/VDO made three different types which were used in the T4 - all which all used different transponder coil to those used in the Golf/Passat etc. Of these three, the one most similar to the Golf also has similar connectors and transponder coil. However, the coil will work in a fashion with the Golf immo box but as the tuned frequency of the coil is different it is not entirely reliable and may result in intermittent reading of the RF device in the key.

The Temic immo boxes are completely different to all of the rest and you cannot use any of the bits and pieces with a Siemens/VDO unit. These are usually the plug-in module type (but just to confuse thingsSiemens/VDO also did a similar style immo box)

The Motometer (which is a division of Bosch) immos are few and far between, they are listed on the BOM for some builds of IDI engined T4 but I have never seen one in the flesh so I can't comment on how different they are. Needless to say they will be very different to the Siemens/VDO units.

Perhaps now you can see why it is important not to take things at face value. One tdi conversion will not be the same as the next. VAG (like all manufacturers) often swap suppliers at a whim (usually cost-based) and this often results in variations in vehicle components. I hope this clears-up any ambiguity that people may have about immo boxes.

As for the baro sensor, it is indeed important. It would be foolish to think that there are no hills or mountains in the UK. I'll leave it at that.
 
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