my tdi conversion

 

first I had to get myself a decent 1z tdi car, in my case a seat toledo tdi sxe of 1995 (before you all go out and buy one please read my warning at the end)

 

which was then stripped to this

 

a stiff drink then tackle this

 

which when removed and tidied up a bit looks like this

please note the seat has a much longer loom than the golf/passat, dunno why but it does which for me was very lucky as it was going in a karmann

 

removed onto pallet with gearbox still attached to make timing belt change easier and so I could lock it at tdc ready to be fitted

 

changed the 1z thermostat housing for a jx one, I had some issues with the housing not sealing as the mounting was not quite identical to the 1z one just a moulding issue but glad i checked before continuing, also replaced the breather as they are notorious for cracking, new one just not fitted yet

 remember to swop the oil pump to the jx one

 

 

bit of cleaning and cutting

 

welding

 

and mount a fan

 

make a hole in a spare space and fit

 

 

 

the 1z manifold points the wrong way

 

so chop it off clean it up and reweld

 and I blocked off the egr and threw that away

 

thats better

 

intercooler has this scoop as well

 

I'm lucky to have a blank panel where the T3 lights were so put it to good use

 

and with room behind the karmann bumper, chavvier than a chavvy thing

 

starting to plumb in nicely, the jx ps pump has now gone and new pipes fitted to the 1z pump,

the blue bit top left is a catch tank connected to the breather pipe as I dont like feeding dirty air into the inlet pipes no matter what engine I'm working on

 

and the bud bottle just happens to be the right size for mocking up

 

 

finish off the pipework, or so I thought

 

then remember I need an air temp sender in there

 

 

 

 

over 4 months, yes FOUR months I,

 

exhausted the internet for clues on 01242, rewired it twice, sent the ecu away to be tested, swapped the maf/air temp sender/n75, tested the ecu in another car, tested the turbo, I even got to the point where I was thinking maybe the pump was faulty but when i spoke to my local diesel specialist he said 'not a chance' and even said if it ended up being the pump he would give me a free one, thats how certain he was so that was good enough for me.

 

it was only by chance that a fellow tdi installer happened to replace his vw ecu with a seat one to try and locate a problem he had that my issue was resolved, his engine instantly went into limp mode with exactly the same fault as mine.

i purchased an ahu ecu/key/immobiliser from a golf and fitted it on mine and fault gone, van drives perfect

 

There is something in the seat ecu that does not like the trimmed down wiring that is used when fitting in a T3, the vw one is quite happy and shows no faults.

 

So the WARNING is by all means use the 1z out of a seat but avoid using the seat ecu

how is the drive now? did you change the gearbox or was that not needed because of the size of the karmann? ie weight/drag. etc.

 

 

also your throttle t,p,s under the floor is that a good place cus of water?? or have you put splash gard there let us know how you get on i might do that get rid of that big cabble feeling? 

Hope ya have good weekend away big smile's