T4 engine swap..ABL to 1Z.....help

blew the engine on my 98 T4 (ABL engine code) and could not find a replacement so thought I would relace it with a golf 1.9 tdi lump from a 1996 car that I managed to buy complete......there seems to be a lot more wires as the golf engine has an electric pump and ecu..........has anyone done this conversion as I could do with some serious help with a wiring diagram......many thanks pete

Edited by petefuss - 25 Jan 12 at 11:21

Is a 1Y not a 1.9d?

Hi it may be a 1z....definitely tdi as has intercooler and turbo........

Hi I searched the T4 forum and then all forums.....gonna clean engine and determine exact engine No.........cheers pete

Hi thanks for that..........very helpful info.....still quite a daunting job for the conversion.....

Wiring is easy,
only use the engine loom from the golf, it's the 3 large White plugs. When you remove loom from golf it comes out with all front lights too so they need spliting out. Easiest way to split is to lay it out on floor, then work from ecu plug remove anything which don't go to the ecu.

You keep the coolant level wire from the t4 and bin the rest.

Best to use the golf clocks too, just swap them out complete with loom.

Hi

Not sure if you are still planning on fitting tdi or if you have finished your install.

I have just fitted 1z tdi in place of a blown 1.9 abl motor. The job was quite straight forward although not all of the information seems to come from one source / page.

I fitted a brand new tdi specific throttle pedal and potentiometer to the std TD pedal box. (still available from VW main dealer)

The ecu, I fitted in the engine bay, (to the left of the fan and battery box on the fire wall)

I also needed to add a length of wire from the W terminal of alternator and attach to one of the white plugs that goes to the fuse box. (if not oil light stays on as ECU rpm feed does not suit T4 dash)

I am looking at fitting 2.5 tdi air box as this will allow fitment of the MAF (air flow meter) which won't attach directly to the ABL air box.

I am also looking to find a 2.5 tdi inter cooler from a short nose T4 with intercooler, in the hope that this will work and give a clean factory look to my install. I'm not sure if any one has fitted an intercooler from the 2.5 tdi onto the ABL 1.9 TD pipe work. I have searched for images on google and found no evidence.

Tim.

Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.

Tim Shettle
www.ultimate-engineering.co.uk
Bristol

Tel/txt 07810 320 464

AFN TDI Panel Van

You only need the lid off the air box, the base is the same on both engines.

The n75 pipe ( black from memory ) can be left loose in engine bay or just cut a notch into the dirty air side and insert it.

Not tried the 2.5tdi inter cooler mod, always fitted front mount ones behind grill, if you go down that route be careful not to cut the ends off the radiator hangs that come out of the rad. They are hollow and oval difficult to plug and it will cost you a new rad......

Edited by dbug - 21 Feb 12 at 18:05

I bought a new 2..5 inter cooler, fitting brackets and hoses, which I hope 2 fit next week. Not sure if this has been done before.

Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.

Tim Shettle
www.ultimate-engineering.co.uk
Bristol

Tel/txt 07810 320 464

AFN TDI Panel Van