Can this be done? Has anyone done it?

I think jus has done it , we will see

Cheers mate, whats his user name? I will pm him.

yo matt!

if its the AAZ engine code its near enough a straight swap

search it by engine code and im sure you will get more info dude

Juz or jus I fink il check if you can't find him

Cheers for your help chaps

It can be done Lazy on the T4 forum loads of info!
think it is not so bad to do either!

Need to get and join that forum proporly so I can view the tech section!

im currently doing this swap myself,

will go with minor a few minor mods nothing too difficult, basically you need to swap a few parts over from the td engine, drill and tap a couple of holes to a larger size and rehome the dipstick. plenty of info on the t4 forum, theres about 10 different build threads over there (mine included).

anden wrote:im currently doing this swap myself,

will go with minor a few minor mods nothing too difficult, basically you need to swap a few parts over from the td engine, drill and tap a couple of holes to a larger size and rehome the dipstick. plenty of info on the t4 forum, theres about 10 different build threads over there (mine included).

Any chance you could send me a link to your thread or others on the T4 forum cheers? What engine code is the engine you are putting in? Are you anden on the T4 Forum?

if you are in the t4 section of the t4 forum click on the engine section then at the top theres a 1.9tdi information library post at the top. All of the completed build threads and documentation is in there. Aggies original thread is a good place to start.

Thats where ive found all the info to do mine,

To summarise converting a 1.9td (abl) into a 1.9tdi you need to

*obtain a 1z or ahu engine from a donor vehicle as well as the engine loom, ecu, immobilizer electronics and chips from the keys
*Purchase new flyby wire accelerator pedal and bracket for an early 2.5tdi from vw.
*swap over your sump,pickup and turbo/inlet/exhaust manifolds from the abl engine
*drill a new hole for your abl dipstick in the blank already in the back of the block and fit your abl dipstick
*blank off old dipstick hole
*drill 2off M8 holes out to 8.5mm and tap with an m10 thread to take drivers side engine mount
*drill 1off M6 hole to 8.5mm and tap with an m10 thread to take drivers side engine mount
*swap over all your other t4 ancillaries such as power steering pump, alternator etc
*Source a 2.5tdi airbox lid

thats pretty much it really, also worth doing the following things whilst the engine is out.

*replacing cambelt, waterpump, auxillary belt, power steering pump, sump gasket, rocker cover gasket, oil seals (if they are leaking)
*fitting a new clutch, the golf flywheel is actually bigger than the t4 one and is compatible with the old t4 gearbox you are reusing. You can either fit a golf clutch or a 2.9 vr6 corrado clutch to it.
*The fifth gear from the golf gearbox can be used in the t4 gearbox to give you a taller 5th gear, reduce engine stress on the motorway, improve mpg and reduce revs.

Im looking to go for more power than the standard engine gives too so have obtained an uprated intercooler (sprinter/lt intercooler) which i plan to fit at the same time as the conversion as well as a decat pipe and then once everything is all running smoothly buy big injectors and off she goes for a remap.



this is the easiest way to do the swap, not the cheapest but in my opinion id rather do it properly, sure you can knock up a bracket and faf around with your existing pedal to save money but for the cost of vw parts designed to mount these exact parts properly in the vehicle you are using why bother??

You could also use the standard intercooler from the donor vehicle no problems.

The airbox lid again allows the golf maf sensor assembly to fit onto your standard t4 airbox base properly, the existing lid can be bodged but why bother?? OEM look is the way for me.

You can also use the golf turbo and manifolds if you wished but you would then need to fabricate a new downpipe. Some people have preferred this route, but the turbos used are either exactly the same anyway or are equivalent in performance so why bother.


any questions feel free to ask, i clued myself up pretty well before biting the bullet and buying everything, im currently in the situation where ive replaced all the bits required,did my 5th gear swap 18months ago so one less thing to do, prepped the loom down to whats needed ready to go in the van, and all the rest of the parts are sat in a big pile awaiting removing my abl engine on Friday. Game on!!

Cheers for all that info, I will start to get the parts up together over the next few months. Cheers again and if you need a hand and I am not working give me an e-mail.

about a year ago mine is on t4 as well,,took me a week to do with the other car there,,is well worth it when it is finished..but just sold mine lol and i fitted the later blue and red dials as well..

juz wrote:about a year ago mine is on t4 as well,,took me a week to do with the other car there,,is well worth it when it is finished..but just sold mine lol and i fitted the later blue and red dials as well..

ive got a t5 intercooler now for sale £60.00

[quote="juz"]

juz wrote: i fitted the later blue and red dials as well..

did you have to buy 1.9 td blue dials or do the 2.5tdi dials fit?

i am aware you have to splice the loom to fit as the blue dials have two connectors whereas the standard ones only have one.

cheers andy

[quote="anden"]

juz wrote:

juz wrote: i fitted the later blue and red dials as well..

did you have to buy 1.9 td blue dials or do the 2.5tdi dials fit?

i am aware you have to splice the loom to fit as the blue dials have two connectors whereas the standard ones only have one.

cheers andy

yea i got 1.9 tdi ones and the surround and yes very hard to wire up but i done it in the end.

How is the conversion going anden?

well the engine is in but got a few bits to modify and sort out, should be up and running in the week sometime

anden wrote:well the engine is in but got a few bits to modify and sort out, should be up and running in the week sometime

Excellent mate! Keep us informed! Was the fith gear swap hard? And would you fancey giving a fellow Dubber a hand to do it once you have finished your engine swap at some point?

did fifth gear swap ages ago, yeah no probs, no idea where my puller is i used though!

Cheers ! I have a 2 leg puller if thats any good? Just let me know when you are free, no rush.

anden wrote:well the engine is in but got a few bits to modify and sort out, should be up and running in the week sometime

How is the conversion going?

sorry for the slow reply, shes in shes running and shes ace!!

cruise control the lot, all working perfect, no leaks no fault codes, wooooosh!

like night and day in terms of power increase over the crappy abl engine!

see u already got the 5th gear mod done, are u looking to sell the gearbox or the 5th gear from it as im looking for one to do the 5th gear mod myself ? thanx

already sold the box to a bloke in stroud dude.

also sold my abl engine too, got a few bits and bobs kicking about but not much left really from the t4