TDI Conversion ( Sharan / AFN ) - My Build Diary

[16vmini]

Finally going to do an engine conversion , was going to be SVX , but sold all that , now going with the 1.9 TDI route.. as so many have started to.

just bought this ....98/99 sharan .. which i think is AHU.. engine code ...? or i have just been told its a AFN engine code ( looked up via reg number )



could not get it to start .. but 99% sure it was the starter , as all dash lights came on , but would not turn over .. check by hand all good.
took starter out , and it would not turn... after a few hits with a hammer it did , then stuck again ...

so taken a punt on the setup .. 200 quid !

just got to go remove it now and take everything i need from the car.

hope i bought the right one ! LOL

Matt

[16vmini]

ok my thoughts...

1) going with a TDI input shaft for my gearbox ( easy to swap ? )
2) trying to keep as much std on donor engine as possible ..rather make new engine mounts to not change turbo etc
3) dont need PAS pump.
4) mod my sump to for turbo drain
5) can these turbo's be re-indexed if i tilt engine ?
6) can i just cut off rear loom in donor car ? and then just take everything forward of drivers door post ( ecu . fuse box etc ) ?

its missing an ECU /control box under passenger seat , from what i rear this is just central locking/window ECU ....

where are engine ECU's found ? behind fuse box i assume ?

Matt

[16vmini]

ok , new starter motor ordered up.. so when i go take engine out i can take the new starter with my and fingers crossed prove it starts and run .. and shows i have not bought a pup !

anyone bought stuff from here :

http://t3-umbau.de" onclick="window.open(this.href);return false;

i see they do an adaptor for the starter motor

http://t3-umbau.de/product_info.php?products_id=1019" onclick="window.open(this.href);return false;

they also do a tdi input shaft and a few other bits ... i know brickwerks sell the input shaft , but have not seen the starter motor adaptor ...

Matt

[lloydy]

Good luck with it I'm sure on b'yard there is some mention of simon getting in adapters for tdi starter?

[16vmini]

Good luck with it I'm sure on b'yard there is some mention of simon getting in adapters for tdi starter?

cheers would be simpler to buy all from him ...

will have a hunt

E D I T , link : http://www.brick-yard.co.uk/forum/tdi-s ... 72561.html" onclick="window.open(this.href);return false;

Matt

[donciuz]

Hi

I have bought the starter adaptor from that german site and it arrived OK. Haven't had a chance to mount it as i'm still waiting for my rebuilt gearbox. But it fits the starter, and comparing with the old starter should do the job. The AHU engine is sitting in a corner...

I also have bought the input shaft from brickwerks. But you should also buy new bearings, gaskets and seals for the box. All of it has cost me a nice sum of money

And thirdly i have bought a turbo adaptor so i'm using a jx manifold and all engine mounts.

[16vmini]

Cheers. I have a fully rebuilt gearbox waiting. So just need to swap input shaft.

Cheers for other advice.

Matt

[16vmini]

ok .. woke up this morning and ordered some parts from germany .. input shaft / clutch poop plate / and starter motor adaptor ...

[16vmini]

ok starter motor arrived today ...

and parts from germany have been posted got a DHL tracking no ....

hoping to take engine out / loom out thursday if all goes to plan ....

Matt

[16vmini]

done first part .. removed petrol input shaft from my spare/rebuilt gearbox



just in case anyone does not know , you remove the C clip thats at the bottom , lift up the reverse gear and just unscrew . simples

now ready for my TDI input shaft....

Matt

[16vmini]

well i took the new starter motor over to the donor car today , and fitted it , it started on the button ! no smoke so well happy !

small vid of it running :

http://www.youtube.com/watch?v=IGvMMbMYtPs" onclick="window.open(this.href);return false;

to save time removing loom , i cut the loom that went to the back !



less lights on the dash ! lol .. but it still started and ran fine.

after allot of swearing i got the engine out !



and a picture of it fitted ! lol :



ran out of time to remove all of loom ! grrrr .. so have to go back .. bloody dash in the way .. going back with a disc cutter !!!

[16vmini]

will need to do something with water pump pully , have read about changing it so you can run it on the wide belt .. so need to look into that

also dont need the powersteering pump as i am running electric pump ... so might be able to drop alternator down as well ?

we shall see

[16vmini]

parts from germany turned uptoday , poop plate , TDI input shaft , and starter motor adaptor to allow me to keep my nice new TDI starter :



will get rest of wiring from donor car tomorrow morning ...

Matt

[16vmini]

just ordered a water pump pully so i can get rid of PS pump /and air con pump

vw pt no : 028 121 031E

Matt

[16vmini]

loom out !



boot full of bits :





and the throttle pedal .. took awhile to get it off .. but i won !



read a few things about blocking off the EGR , not sure to do that or not at the moment....