-Clean and degrease engine bay. - Clean and strip the two wiring looms and make one loom - source a set of tdi pedals with the switches and potentiometer - buy the volvo engine and "bits" - decide what to do about a gearbox. I'm not sure if the 2.4 gearbox can cope with the tdi ( 140hp from volvo).
The old girls looking a bit sorry for herself now but I'm so full of enthusiasm to get her finished. Ive been out on the drive every spare hour doing a "bit". Must get some better lights outside.....
Believe the t4 gearboxes are all pretty much the same, slight variations in gear and final drive ratios. A heavy duty golf box with larger diff and different angle for mountings. So a golf box won't fit. You can use a 5th gear from some golfs to give you a better cruising gear, or spend a major amount of wonga and get a bolt on 6 speed conversion Ttfn Glenn
Progress report-- To be honest, not much. Why is it, when you're waiting for payday, it takes so long?
I bought a loom for a 2.5 tdi off ebay and spent all week downloading wiring diagrams and trying to figure out where all the connectors go. I got it sussed eventually. However, that was only engine side of the bulkhead. I still need to sort this lot that goes to the pedals and fusebox .
What a pain the butt!!!
Sadly, my engine savings took a bit of a dip this week when my daily driver peugeot 306 decided to break a coil spring and put it through the tyre...gutted. Was gonna scrap it at the end of the month. Definately scrapping it now.
So now I need to find a gearbox from a 2.5tdi (for a sensible price) and a complete engine from a Volvo v70 or 850 turbo diesel. There arent many complete cars about. There are a few but they have high mileages. Not too bothered about mileage as I will refurb most of the head. Keep em peeled for me guys. Volvo v70 or 850 2.5tdi.
The 2.4 gearbox will have lower gearing than a tdi one. Tdi got two different boxes, the 88 (non-intercooled) has the 02B box which as stated above is a golf box beefed up. The 102 got an Iveco box which VW called the 02G which is higher geared and has a different gear linkage. If you're fitting a Volvo lump I'd go for the 02G.
I bumped into a guy at mcdonalds today with a 102hp t4. He kindly let me poke about under the bonnet. I think the blue plug connector goes to the top of the coolant outlet on the front of the block (thermostat housing?).
So thats the bulkhead side wrapped up.. Quick question though -
My 2.4 loom has 2 wires coming from the alternator A blue wire which goes to pin f3 on the fusebox and a red/white wire going to pin f9. I think this red/white wire is for a rev counter feed? My 2.4 doesnt have a rev counter. The 2.5 loom I'm fitting does not have this red/white wire from the alternator. Where does the 2.5 rev counter take its feed from?
Today I carefully extracted the crappy aftermarket alarm that had been badly fitted and droped the fusebox down for a better look at it.
Jesus its going to be hard to fit this new loom to the back of the fusebox!!! I think the only way I can do this, along with the new pedal box is going to be to remove the complete dashboard
Ok on to the next "little job". In order to fit this new loom, the fusebox will need to be dropped significantly. Also, as I'm fitting tdi pedals, its gonna make sense to remove the steering column to get to things. Looks fairly easy except the bracket is bolted in with those bloody rounded off security shear bolts. Why do they fit them? How the hell do I remove them? Think its big drill time
Shes a bloody heavy lump of iron but the stand is good for 450kg. Still scary mounting it all off four bolts!! Thank god I can put it in the garage and work on it while its dark outside and they are watching cr#p factor and cr##ly come dancing.
Nice project. Volvo engines meant to be stronger. If you going for power-mechanical pump. For economy-fit ECU. Thats what I'm currently doing, but gone easy route- full golf Mk3 TDI 1Z donor from salvage auction. Good luck with yours, will be following.
1984 Fiat 126 Brown - SOLD 1993 Audi 80 - work hack 1994 VW Golf 1.4 L - SOLD 1997 VW T4 Syncro pickup - looks like new project 2005 Audi A3 Sportback TDI - daily / euro trip bus
Have made a bit of progress this week. I've stripped a lot off the block that isnt needed (Volvo mounts etc) and removed the inlet manifold and auxilliaries.
The massive horizontally mounted oil filter and cooler bracket has been removed to be replaced with a Vw vertical filter and bracket ( which I stupidly threw away with my old engine). The one thing that has pleased me so far is that the block really is exactly the same as the Vw units. All mounting holes in same places and I can even fit my mounting brackets from my 2.4 non turbo engine🖒🖒🖒🖒 I was worried that I would have to shell out for auxilliary setup from a turbo engine but no, everything is transferable. Only thing I really need to source is a dip stick tube as this also has the turbo oil return pipe. So far all going to plan. I'll strip as much as I can and replace crank seals before fitting. Part of me wants to get it all in and running ASAP but I really want to detail it while its out. I'm aiming for this sort of detail-
The last picture shows the triangle of holes where the mounting bracket and auxiliary belt tensioner were bolted on the volvo. These same three holes are now used for the VW transporter engine mounting bracket. Simple
The two fuel lines have also been removed and binned as the T4 fuel lines run on the other side of the vehicle.