You might want to research gearbox torque, the PD engines generate huge torque that are beyond the range of the box fitted to the ABL. The box fitted to the ACV would probably suit better.

 

Read this: http://www.vwt4forum.co.uk/showthread.php?t=408537 and read the 02m 1.8t thread, most of the issues you encounter will be the same, mounts, sump, oil pickup. Talk to vagtronics about getting a loom made. With 02m you are either looking at an adaptor plate to put the diff in the correct place, or running horrible driveshaft angle.

Post up some pictures and write a how to, it'd be nice to see one of these get finished!

 

Good luckT: Really hope you see it through and complete the engine conversion...as you say its been mentioned a few times, but I haven't seen anyone see it through to the end!

On paper, it should be awesome

 

@Solarboy I'm using a 6speed o2m gearbox, torque is fine!

@d-9 cheers! I'm looking at getting a half driveshaft and a support bearing made up for the drivers side, passengers I'll decide one the engine is mounted.

@Mike-S Thanks, I'm determined to get this finished, and I'm going to try my best to make it awesome! Plenty of money going into this build. I'll keep y'all updated.

 

Heres the thread on 02m, looks like they used a 4wd quattro/4motion box to reduce the length of the drivers side shaft, using shafts that are a mix of golf and T4: http://www.vwt4forum.co.uk/showthread.php?t=371766

TBH a standard 02b would probably be ok with a PD130, Im running a nominal 330Nm through one and it hasnt yet exploded

If you do manage to figure out a good way of making the mounts for the PD130 with 02m, please post up the templates! It'd be nice to have another alternative.

 

Okay, so a bit of an update for ya. Engine fits well, I've offered it up and did a bit of jiggery pokery with jacks and it looks like the driveshafts fit nicely.

Old ABL out

First trial offering

Driveshafts are close, small adjustment needed

Cambelt side gap

Gearbox side

Next up, engine mounts!

 

Fitting the driveshafts, the golf shafts have different outer cv joint, so I swapped them for the offside shaft.

So, this is the first rendition of the engine mounts. I'm hoping i have the engine in the right position, the driveshafts all line up and sit at the right height. I also decided to use two gearbox mounts from the original engine, as the gearbox ones were a more usable shape and size so fit a lot nicer.

Waiting for the second mount to arrive, so I made a crude temporary jobber

 

So with the engine mounted, it sits very nice.

Sat at a similar height as the old abl lump
http://imagizer.imageshack.us/v2/640x480q90/924/Il3Dzb.jpg

Though the sump sits at about half an inch lower than the sub frame, so I'm going to need a shallow sump and a guard

Offside shaft sits at a slight angle, nearside is pretty much perfect

 

MMMM

Very Interesting

I used to run on old passat and PD lump is a cracker. Plenty of tuning potential as well.

What gearbox are you running? Six speed?

The drive shaft looks a little uncomfortable at that angle but with a little drop and some more weight on the front end should see things fitting perfectly.

Good work and fair play for having a go.

Fully subscribed! T:

 

Goodluck with this

subscribed.

 

Hi. How project is going ?
I've swapped my ABL for AFN and did some modyfications for over 170hp, gearbox has been upgraded with faster main gear from EWB and fifth one from T5, now is nice to ride.
PD engine is more powerful, hudge torque faster available than VP engines, will be nice to drive plus 6 speed gearbox.
Am keeping fingers crossed, regards. T:

 

Good luck with your conversion
My 02M will have been in and running in my bus two years come April . Haven't had a single problem,
I only wanted to improve the feel of the gearshift as in the amount of gearshift movement.
Maybe when the weather gets better...... If I still have it
What made you choose the PD ?

 

What made you choose the PD ?

Basically because i had one kicking around that i had just rebuilt completely, so I just used it. I'm more a fan of the non pd engines, but the pd is easy power straight up.

I'm toying with the idea of doing this (if the box will mount on to a AHU bottom end); any chance I could get a look at how you've mounted the box (at the bottom)?

Also, are these boxes not cable change as opposed to the rod system on the t4? How have you implemented the cable system?

Cheers!

I haven't got any pictures on the bottom mount, but its really simple. I cut the old mount from the abl in half, and welded it to a straight piece of steel. on the end of the steel is part of a golf dogbone mount, modified for the different angle.

As for the gear cables, I just removed the old system completely and shoved the golf cable system inside the cab. The shifter sits a bit further back at the moment and I'm going to have to get a custom stick because the golf one is a little too short

I'll get some more pictures tomorrow.

 

I'm toying with the idea of doing this (if the box will mount on to a AHU bottom end); any chance I could get a look at how you've mounted the box (at the bottom)?

Also, are these boxes not cable change as opposed to the rod system on the t4? How have you implemented the cable system?

Cheers!

 

Yes the box is a cable gearshift.
I took the complete set up from the Audi and fitted to the van
Didn't have to mod the van at all. Mounts above fuel tank . Inside the van looks as nothing been changed.

 

Yes the box is a cable gearshift.

I took the complete set up from the Audi and fitted to the van

Didn't have to mod the van at all. Mounts above fuel tank . Inside the van looks as nothing been changed.

Cheers for that, without being able to get out there (it's either freezing or wet!) it was beginning to play on my mind. I'm not sure how the Audi shifter differs to the golf, but I'm thinking welding and extension should do the trick in terms of length.

 

So a progress update for ya.

These turned up, Intercooler, aluminium hard pipes and all the silicones. I'm using 63mm pipes just so I dont have to upgrade in future if I want a bigger turbo set up.

Intercooler sits nicely under the slam panel, I've welded some mounts underneath the radiator for the intercooler (pics later), and there is plenty of space between the engine and the wheel under the chassis leg for the pipes from the turbo.

I butchered an old egr valve for its flange and welded it onto the end of an aluminium pipe.

Bolts directly to the manifold

The old power steering pipes were the wrong fitting for the pd pump, and were too short. So I had custom pressure hose made up.

 

Cheers for the info.

As the days go by, I'm thinking more about changing the engine orientation, which would mean going for a bottom mount turbo. Is there a lot of room behind the head/block to stick a decent sized turbo in?

 

Well I've fitted a gt1749vb turbo onto this asz engine. There is loads of room under the bulkhead down where the abl downpipe goes, made life a lot easier to fit my engine in.

 

That is good news. Maybe I'll try a test fit with the top mount gt2052v I have and the spa manifold, once I've figured out mounts (and had them made up) for this engine.

Have you got yours fully running yet?

 

This is the bottom engine mount that I made up, using half the old mount.

I actually finished up the wiring this morning, and shes not running like a dream. Going to get her up on the ramp tomorrow, give her the once over then see how she drives

 

and shes not running like a dream.

Edit, she IS running like a dream!

 

Awesome. I think you could well start something with this. If the 1Z goes wrong at some point, I'll definitely look into sticking an ARL in there.

 

Good to hear its running. I'm also looking at doing a PD very soon and this thread is a great help, as I was a little worried about turbo and bulk head clearance which you've shown isn't a issue A:

 

Good work, really interested in popping over to take a look at this sometime.

 

Pulled the van shifter today, I'm failing to see how the 02M one fits straight in:

 

It doesn't fit straight in. I've mounted mine inside the cab a bit further back than the old one and welded the hole for the old shifter with only two holes for the cables. The shifter box itself is mounted to a frame I fabricated and welded to the floor so I didn't have to take the tank down to bolt it.

I'll get some pics for yas, been mega busy recently

 

Ah right. I'm thinking maybe the Audi selector that vanhead used is different as he didn't have to mod the van at all.

The plot thickens.

 

Audi or VW the 02M shifters are the same. I'm looking at mounting my shifter 'motorsport style' on stilts