Almost Done

Here is a few pictures of the conversion before I take it for a road test. Everything should be all right... but we never know.

TDI Conversion

The converted oil pan is a combo of an 1.8T oil pan and the bottom part was fabricated and welded by a machine shop in Calgary. Even if it look really good on the photo, this is the only thing that I would do differently. As soon as I have installed it on the engine on my first conversion it started leaking, the problem is that the welds are porous and so the oil slowly make it's way thru the aluminum. Hard to believe but true, so I removed the pan and used some gasket maker from Permatex that is specific for oil pans. It did help a lot but it's still leaking a bit, and that really bugs me...


To suport the engine and transmission I'm using the 2 transmission mount at one end and the Jetta mount at the other but that is not enough to secure the transmission and the engine together and stop some of the vibrations/movement while driving the van. I'm not trying to "Fast-Foward" this part of the conversion. To solve the problem I have made these 2 motor mounts that are bolted to the bell housing, engine and tranny. I'm using the WBX rubber mounts and also the modified WBX bar that used to be at the back of the engine. The bar will be put in place at the same time as the skid plate.

TDI Conversion

I have installed the ECU and the TDI fuse box inside the van on the left side, that way they will be away from the elements. To make sure the van doesn't become too noisy because of the hole I made these 2 plates of Richlite to seal the compartment, the top one is bolted to the bottom one that is threaded. A piece of under mat is sandwiched between to seal the whole thing.

TDI Conversion

There will be 2 oil switches, one for the ECU and the other one for the instrument cluster. The adapter can be found at California Imports in Vancouver.

TDI Conversion

What a mess... Soldering the wires to the cluster, the electronic gas pedal, brake light/ cruise control switch.

Here is the TDI harness, in fact this is what the ECU needs to run the engine.

Finally done with the front wiring, these 2 gray cables have 12 wires each and they do the connection between the ECU/engine and the front of the van.

TDI Conversion

This is the big Jetta motor mount bolted to the 1/4" steel angle.

Once installed to the back of the van and bolted to the frame this will support the engine at one end and the transmission mount will support the other end.

I'm using a Jetta/Golf clucth kit, this is made possible by buying this shaft from Winkler in Germany. No more WBX parts in this Diesel bell housing.

Here is the link.

http://www.vw-winkler.de/product_info.php/info/p118_Clutch-shaft.html

TDI Conversion

I made this bracket to hold the the Jetta main fuse box, and installed the glow plug relay next to it.

You can see the fuse box that will be used for the starter, glow plug and more.

Vacum reservoir and control valve.

I have used a Eurovan expansion tank because of it's bigger size and the bracket that hold it is also available. That help the installation to look clean and saved me some precious time.

Cleaning up.

With the engine out it's time for a good clean-up, repositioning the fuel hoses and installing the new TDI wiring harness.