I’ve made a start on my VW 1.9 TDI conversion into my MK1 swb and thought I’d start a thread for the conversion, however I maybe a bit slow to update as time on here is precious time in the workshop building
I got myself a 2004/2005 VW Passat 1.9 TDI AWX engine code so 130 bhp for the engine and any other bits I might need for the conversion, I’ve got the engine out complete and ECU and engine loom and stripped back the dash loom of the Passat for the plugs that plug to the engine loom, I had planned to use a MT75 gearbox and adapter plate to mount the two but decided against it recently as I don’t want to cut the Mk1 about for the MT75 to fit and faff around with a prop shaft so after much deliberation I’ve decided to use a type 9 with the transit bits fitted so stick is in right place, two reasons for using type 9 are, 1; a bellhousing is available off the shelf from RWD Motorsport to mate the type 9 to VAG 4 cylinder engines (they list it for fitting the petrol 1.8 turbo VW and Audi engine but also say it fits the 1.9 tdi’s) and 2; I won’t have to cut the van about for the type 9 or muck around sorting a prop shaft like I would for the MT75. I know the type 9 is not overly favoured for the Transit but my theory is, it’s a swb van not being used to carry heavy goods, I’m going to uprate with better bearings etc and providing I don’t give it lots of abuse and drive it accordingly I think it will be ok, if not I’ll reconsider my gearbox options for it, I’ve got a few transit type 9’s spare now plus a car V6 type 9 which I may even use for the conversion.
So I’ve got my bellhousing got my tdi engine out and got the V4 and gearbox out of the van in preparation, over this weekend I set about mating type 9 to tdi engine with the RWD motorsport bellhousing and this is when I realised that they drill the bellhousing to gearbox holes so that the engine and gearbox are level mounted as apposed to the engine being ‘leant over’ in its VW installation, there was a solution to this as the rear face of the bellhousing is concentric to the centre bore so I was able to redrill the holes so now the gearbox is level while the engine is canted/leant over as per original VW installation, bonus. I need to muck around with the clutch still and clutch operation is by means of a mondeo hydraulic release bearing assembly (bell housing is already designed/machined for this)
Ive temporarily got the engine and gearbox in the van ready to fabricate engine mounts and get everything else fitting up before pulling it all back out again to paint engine bay, it needs to go slightly higher in the bay and back a little more to get gearstick to line up with original hole in the floor and to give a little more space at the front for radiator but it’s tight to say the least!
Some pics of where I’m up to before updating again.