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Golf Loon
26-02-2008, 08:32 PM
Ok, so I was lucky enough to come across a real cheap accident damed 2002 model TDI T4 with 77,000kms on the clock.

The body was rooted, but the running gear etc is all good. After umming and aahing for a while as to finding a van for the conversion, the choice was made.

My work van is a 2L 4 cylinder 1993 build van, but is very straight and completely rust free. I ideally wanted a later van, so I didn`t have to swop dashes etc, but after looking at all the rusty and battered cheapies around, I am gonna do my one. It also has no power steer or A/C, so am gonna fit that from the donor car too. Phew.

Stage one of stripping the TDI was completed a couple of weeks ago, as I needed the space, so the shell had to go.

Here is the whole front subframes and engine and box of the TDI, on a trolley ready to go.

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff046-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff047-1.jpg

Stripped my van out pretty fast. Uuuh oh, we are in it now....

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff049-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff050-1.jpg

Withe beau the crazy American to help, anything is possible :)

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff053-1.jpg

Golf Loon
26-02-2008, 08:39 PM
Did the timing belt before we put it in. Safety first :)

Engine hanging in by a few bolts....

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff054-1.jpg

loverly power steer

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff056-1.jpg

AC Unit, Booster, MC, Shift linkages are in

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff058-1.jpg

Diesel exhaust system and the rear disks and axles for good measure, mine was drums.

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff060-1.jpg

Starting to look like a van again.

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff063-1.jpg

Wiring

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff067-1.jpg

Wiring

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff068-1.jpg

Golf Loon
26-02-2008, 08:40 PM
Finally dash, I`m gonna have the TDI clocks, cool blue faces and the badass steering wheel and airbag system

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff069-1.jpg

Front end coming together

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff070-1.jpg

Modified the airbox, as my guards dont have louvres, power steer bottle is a tight fit

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff072-1.jpg

Gonna finish the inside, fit an amap and stereo to combat the diesel noise and hopefully finish it tomorrow.

GoLfMan
26-02-2008, 09:42 PM
that looks awesome Matt :)
should be a good power increase over what you had...

mollins
27-02-2008, 09:50 AM
top work.. looking good..

should be sweet to drive when its finished!
Diesel will be sweet for pulling that crazyass trailer of yours

Did you fix the back door?

mollins
27-02-2008, 09:51 AM
btw.. you need a fully sick bonnet scoop for your intercooler man

jets
27-02-2008, 09:54 AM
Great work loon, looks like a lot of work. I wouldn't like to pay to have that done. How long in hours did it take? You have become the resident expert on how the TDI comes apart. Thanks for taking the time to take pics & sharing it with us all.

Mischa
27-02-2008, 10:30 AM
btw.. you need a fully sick bonnet scoop for your intercooler man

damn you beat me to it! baha. best thing about a diesel: leaving the douchebag in a fully sick mobile behind you in a cloud of black smoke :D

william
27-02-2008, 10:49 AM
i bet its finished now i left beau at 10:30 ish he did night shift and i bet its emac pics please

Golf Loon
27-02-2008, 09:12 PM
Thanks jets, glad someone is reading this.

Forgot the camera today. Car is 95% finished. Got to find a few bits of plastic trim and bolt a few things back together.

Got it registered today! Yay. Blue slip with change of engine capacity and fuel type. No engineering required as the vans were sold with those engines :)

Got the AC regassed yesterday. Thanks Oli. It is freezing. It also comes out of all the vents, not jut the inner two like on the early vans.

Rear brakes started scraping bad on the way back from rego. The pads are cactus. Couldn`t drive it any further like that. Will get some disks and pads tomorrow and make it sweet.

It took two VW mechanics a week of long hours, late nights and lots of coffee and v energy to do the conversion. I would want big dollars to replicate the feat for a customer.

Yes I changed the door Mollins. It seems that the rear wiper was an option, as the donor door did not have any wiper. It did have provision for the motor to be mounted though. A holesaw sorted it :)

First roadtest today. It doesnt seem much faster than the 2L, but you dont rev it the same and it has loads of midrange torque that the 2L did not. Should tow the trailer well, but not get me in trouble by going too fast. Engine is not as noisy as it was with no carpet, but could have just been drowned out by the scraping brakes.

Finishing it tomorrow and bringing it home hopefully.

evorobin
27-02-2008, 09:32 PM
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/EbayCarStuff054-1.jpg

Bungees doing a pucker lush job there :D

Great writeup mate!

Golf Loon
02-03-2008, 07:59 PM
Back brakes ridiculously bad.
When the pads wear out children and the metal scraping becomes very loud, change em.

http://www.vwwatercooled.com.au/forums/images/imported/2008/03/2ndmarch014-1.jpg

I now have new discs and pads and the car stops well now.

Using a bit more fuel than I thought it would, but that might be the driving style. Booooost is fun though and you can annoy Commodores :)

TDI springs make it very high and unweildy at the back, might put the 2L petrol ones back in. It used to handle better as a petrol.

Jarred
02-03-2008, 08:20 PM
good converion there mat.. you'll really notice it once you start haullin stuff with it, without breaking a sweat! now chuck it on air bags, and it'll all be pimp
hahaha lmao

ontarv
02-03-2008, 09:22 PM
dam looks like you've been busy
sleep only a option ay!
nice work

Golf Loon
08-03-2008, 10:20 AM
Finally took a couple of pics.

http://www.vwwatercooled.com.au/forums/images/imported/2008/03/5thmarch003-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/03/5thmarch004-1.jpg

Still high at the back with the Diesel springs am gonna put the petrol ones back in.

Ran a tank of diesel through it, got 600Ks on the tank, but towed two cars for 150ks of that and drove like a loon the first day.
Just put in another tank, we`ll see what I get this time.

Corey called round. Hes the mad one with a T4 on Airbags.
Pics are with the front right up!!

http://www.vwwatercooled.com.au/forums/images/imported/2008/03/5thmarch013-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/03/5thmarch012-1.jpg

Jmac
08-03-2008, 09:26 PM
Mate just got round to reading all of this, top stuff mate, great to see someone still into doin stuff like that, i left all of that back home and loved doin it. Last one i did was a 85 Mk2 Kjet to an ABF set up . Mate interesting to see a VW sign on the van can you do that??? Reason i ask as you know i do them up here in Brizzy but couldnt find anywhere on the net to see if i could put Porsche, Audi and VW on my van. Man you look like you are doin well. Ive mentioned before next time im in Sydders ill call in - Minus overalls LOL
Jmac ( and dont say you have a spare set LOL)

Golf Loon
08-03-2008, 10:27 PM
Thanks Jimmy. I like doing conversions, but they always take so long.

Dunno about the legalities of the VW, its an ebay sticker! I do goto Barlo World with it sometimes and no-one has ever said anything.

You are welcome anytime man, come and have a drink and a look at my toyshop ;)

Jmac
08-03-2008, 10:43 PM
Yeah i suppose they would have to conform to a certain size etc and that one you have is BIG and looks great. i must say lookin good all round there mate. I might put the transfers on and hey whats the worst that can happen ( sorry i didnt know hey ) Not like im a big fish mate - irelevant until i steal all their customers LOL
Cheers:D

Golf Loon
08-03-2008, 10:48 PM
Yeah I did have 2 metallic see through signs on the back door windows till a trailer accident destroyed a barn door. Now I only have one VW sign and need to get the signwriting redone. I get heaps of calls from the van and the odd cheeky text ;) And you look professional when you rock up somewhere. Yeah ignorance is the answer, worst case they`ll make you take em off

Jmac
08-03-2008, 10:52 PM
Yup doin it mate cheers, ill say you told me so LOL:D:D:D

Volvo Driver
02-05-2008, 07:32 PM
That's what I wanted my parents to do to our 2.4 idi, or even just put the turbo on, man that thing was slow, and I hated the fact only heat came out the sides, but I thought the A/C came out the centre.

And even with more power they get better fuel economy, which is awesome.

irsa76
04-05-2008, 07:50 AM
So the next conversion going to be the Syncro drive line? Last time I pulled the engine out of a TDI T4 it had the auto attached, THAT was a fun job.

revomaster
06-09-2011, 10:37 AM
Good evening,

My name is Mario, I'm from Quebec Canada

I'm having the same kind of project as your in 2008, I was based in Poland for a while for my work
and since the Canadian Government didn't accept my request to import my T4 TDI 2002, I decide to bring the gearbox and engine back with me in Canada as spare part in a container with the rest of our goods, in order to bypass our import system.
I also bring the complet ECU, ECU Harness, ACV Engine, ECU and Harness, Dashboard, down pipe, and some other things just in case.

It took me a while to reinstalled the complet kit, because I was looking as you for something clean in order to install everything, because in North America they stop import those Eurovan (T4) in 2003 and what remain on the road are very rusty. So I finally found a 1999 perfect and clean weekender body with climatronic to install the complet kit show room body (nothing to touch perfect paint and the rest of the mechanic A1).

I remove the VR6 with Auto Gear from that T4 and reinstalled the complet kit TDI (ACV) with Manual Gear cluster, wires (Harness) etc.

I tought my project was almost done, but since we took that engine in 2007 from Europe and took a while before installing everything,
I'v lost a little on the memory side... I bought the T4 manual from bentley and the T4 Workshoop Manual (Green Book) from Brooklands that book is covering:1.9 (ABL), 2.4 (AJA, AAB), and 2.5 TDI (ACV, AHY, AJT, AUF, AXG, AXL, AYC) from 2000 on...


The probleme I'm dealing with actually is: Wiring stuff, I put everything on place, but I'm having issue to start the engine.
I"m almost sure it is a wirring issue, since we have several connectors remaining free.

Engine turn, but it doesn't start sometime he almost start, but it react as if the shut off valve on the injection close because of missing 12 Volts, but that is not the case, there is power. Since i'm starting from far in that project, i'm a bit lost now.

My main issue at the moment is that I have several cables from the cluster that I can't park, some connection are missing.
(I mean extra connectors from that I can't part on the fuse block and some colors connectors 1 and 2 pins that I can't connect, since I don't fine the matching connector (Cluster harness) Cluster issue: no blue backlight, left and right flasher harrow not blinking, the temp I don't know since the engine doesn't start, and the most of all no communication with the OBD2 connector.

I will really appreciate if you can give me a hand with my project.

I will be waiting for your reply, hope you can give me some advises.

Forward to hear from you soon, if you can send me a phone number PM to my email
I'll get in touch with you to discuss more in details.

SKYPE USER : pokerdeqEMAIL: revomaster@oricom.caCheers

Mario

revomaster
06-09-2011, 10:46 AM
Good evening,

My name is Mario, I'm from Quebec Canada

I'm having the same kind of project as your in 2008, I was based in Poland for a while for my work
and since the Canadian Government didn't accept my request to import my T4 TDI 2002, I decide to bring the gearbox and engine back with me in Canada as spare part in a container with the rest of our goods, in order to bypass our import system.
I also bring the complet ECU, ECU Harness, ACV Engine, ECU and Harness, Dashboard, down pipe, and some other things just in case.

It took me a while to reinstalled the complet kit, because I was looking as you for something clean in order to install everything, because in North America they stop import those Eurovan (T4) in 2003 and what remain on the road are very rusty. So I finally found a 1999 perfect and clean weekender body with climatronic to install the complet kit show room body (nothing to touch perfect paint and the rest of the mechanic A1).

I remove the VR6 with Auto Gear from that T4 and reinstalled the complet kit TDI (ACV) with Manual Gear cluster, wires (Harness) etc.

I tought my project was almost done, but since we took that engine in 2007 from Europe and took a while before installing everything,
I'v lost a little on the memory side... I bought the T4 manual from bentley and the T4 Workshoop Manual (Green Book) from Brooklands that book is covering:1.9 (ABL), 2.4 (AJA, AAB), and 2.5 TDI (ACV, AHY, AJT, AUF, AXG, AXL, AYC) from 2000 on...


The probleme I'm dealing with actually is: Wiring stuff, I put everything on place, but I'm having issue to start the engine.
I"m almost sure it is a wirring issue, since we have several connectors remaining free.

Engine turn, but it doesn't start sometime he almost start, but it react as if the shut off valve on the injection close because of missing 12 Volts, but that is not the case, there is power. Since i'm starting from far in that project, i'm a bit lost now.

My main issue at the moment is that I have several cables from the cluster that I can't park, some connection are missing.
(I mean extra connectors from that I can't part on the fuse block and some colors connectors 1 and 2 pins that I can't connect, since I don't fine the matching connector (Cluster harness) Cluster issue: no blue backlight, left and right flasher harrow not blinking, the temp I don't know since the engine doesn't start, and the most of all no communication with the OBD2 connector.

I will really appreciate if you can give me a hand with my project.

I will be waiting for your reply, hope you can give me some advises.

Forward to hear from you soon, if you can send me a phone number PM to my email
I'll get in touch with you to discuss more in details.

SKYPE USER : pokerdeqEMAIL: revomaster@oricom.caCheers

Mario