1.9tdi Into my Bay Window Jurgens '79.

skirk

Okay.

I have finally decided to bite the bullet and go TDI with my Jurgens Bay. I have a few questions if that is okay. Thanks in advance for putting up with a complete novice re the conversion. I have gleaned the following over the past year or so but it is only limited knowledge so please point me in the right direction.

Required.

AAZ Engine 1997 and older.Not fly by wire. Though have seen a T25 with a 1z engine with the potentiometer installed in the footwell. So can I install fly by wire ? I have seen quite a few 1998 golfs with TDI. What engine would this be ?

Early T25 Gearbox cone or whatever the technical term is.
T25 diesel Oil sump.
T25 Diesel engine mounts.
Cooling parts; radiator etc.
Heater matrix for cab at least.

Thanks in advance for any invaluable advice.

trev · Posted: Thu Aug 21, 2014 10:11 pm Post subject:

the AAZ is a turbo diesel engine, not TDI. TDI is a direct injection engine with electronic pump control, the older turbo diesel is an indirect injection engine with cable pump control.

The AAZ is 75BHP, the lowest of the TDIs is 90BHP (1Z/AHU engine found in mk3 Golfs etc but the AFN is very similar and has 110BHP)

The bay window bus has a taller engine bay "roof" than the type25 so you can get away with bolting the engine to the bay window gearbox with an adapter such as KEP supply. No need for T3/Type25 sump, mounts etc. Either way, you'll need to build up a subframe to carry the engine.

You don't need to put the throttle potentiometer in the footwell. You can run the stock cable back to the engine bay as it does anyway and use it to pull the throttle potentiometer remotely. It does away with lengthening a pile of wires. Just make a bracket to carry the throttle potentiometer and the cable.

One other thing: I've got a 1Y engine (1.9 indirect injection, 64BHP) on a "2 litre" bay window gearbox for the last year now. It'll return 40MPG but is quite noisy at cruising speed. I'm going to ditch the whole engine/gearbox conversion and start over with a TDI and the 5-speed gearbox from a Passat (b5, 1998 onwards) turned upside-down. It'll make it quieter and hopefully more fuel efficient. You should consider this conversion as you'll wish you'd done it in a few months time Happy

skirk · Posted: Fri Aug 22, 2014 8:54 am Post subject:

skirk · Posted: Fri Aug 22, 2014 9:04 am Post subject:

Sorry one added question.

What about wiring. How much more difficult to do a 1z than a AAZ ?

Thanks.

Smoothlookinbay · Posted: Fri Aug 22, 2014 1:29 pm Post subject:

In response to your question about adapters/sumps; if you use the t25 bell housing on your gearbox it will tilt the engine over to 50? degrees, requiring the use of the t25 wedge sump, oil pump/pickup etc. if you use a KEP adapter you can have the engine at the same angle as the car so it won't require the different sump etc.
Hope this helps,
_________________
It WILL be ready for the summer, just like it was going to be ready for last summer. And the one before that...

skirk · Posted: Fri Aug 22, 2014 2:12 pm Post subject:

Cheers for that.

trev · Posted: Fri Aug 22, 2014 7:20 pm Post subject:

the AAZ would need just a few wires to get it running:

switched live to the glow plugs
ignition-switched live to the fuel cutoff solenoid
wire to the coolant temp sensor (and a gauge wired into the dash of the van)
earth
oil pressure light

that's about it from memory. Zero electronics, just electrics.

any injector-pump TDI (as opposed to later PD or CR TDIs, I know nothing about those!!) will need the ECU and throttle potentiometer from the donor car. Best to grab all the engine bay electrics back as far as the fusebox. I can't go into it in too much detail as I had help with mine and can't remember most of it but you can run the donor engine electrics "standalone" inside your van once you supply a few lives and earths. It's not a massive job but I was glad of the guidance

you can't mate the engine directly to the bay window gearbox, you need an adapter like KEP sell. However, take it from me, you and the engine will be happier if you plump for the upside-down B5 Passat/Audi A4 5-speed gearbox. Even the best bay window 4-speed gearbox isn't ideal for the TDI engine. Unless you remortgage your house and have a 4-speed gearbox "built" to accomodate the TDI, gearing-wise.

'98 Golfs and Passats are both good engine donors, the engine arrangements are different, Golf is transverse, Passat longitudinal so the sumps are different shapes. If you're going to go 5-speed just look at Passats /A4s as donors. Wasting your time with Golfs due to the sideways gearbox being no use to you.

skirk · Posted: Sat Aug 23, 2014 1:24 pm Post subject:

Cheers Trev. Thanks. Would a 1999 Passat Tdi work as a donor car ?

Thanks again

trev · Posted: Sun Aug 24, 2014 10:54 pm Post subject:

yep!!

skirk · Posted: Mon Aug 25, 2014 11:07 am Post subject:

Cheers Trevor. I have been searching for cars and the Passatt engine codes seem quite straightforward. I can get a 1999/2000 car with the correct engine. Golfs seem to be a little more confusing. Are any of the mark 4 TDi engines suitable without too much electrickery ?

Sorry for all the questions.

trev · Posted: Mon Aug 25, 2014 6:15 pm Post subject:

yeah the golf engine would work too with the same amount of messing with the electrics but since you'd need the passat gearbox to complete the conversion, you might as well get the passat donor

skirk · Posted: Mon Aug 25, 2014 6:30 pm Post subject:

Cheers Trev for all the info. I have got a few cars to see golfs and Passats. If I can't get the Passat I will have to give the golf a go with the 6 rib gearbox. May not be too bad in a Jurgens as over 65 can be a bit hairy !!!