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Eurovan 2.5 TDI and 5-speed swap!
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gresh125
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PostPosted: Mon Nov 10, 2014 1:11 pm    Post subject: Eurovan 2.5 TDI and 5-speed swap! Reply with quote

I am swapping the vr6 engine in my wifes 2002 eurovan for a 1997 2.5tdi engine from Germany.
I was not able to find much on this specific swap so I though I would document for you folks. questions and comments are welcome thanks

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I purchased this van many months ago with what was though to be a stretched timing chain it ran roughly at times then fine other times, really strange. clean inside and 130,000 on the clock.

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and so it begins.

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the vr6 is out what a mess of wires and hoses. I sold the engine and trans off pretty quickly glad to have them out of the shop.

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The tdi arrived! I purchased it from an importer in so Ca.
decent price for the whole thing minus shifter. he even left the wiring harness intact no cut wires. This should make the job actually possible ha.

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egr tube looks great!

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removed the original auto foot pedal assy. along side the manual set up.
appears to be a direct bolt in replacement.


Last edited by gresh125 on Sat Nov 15, 2014 1:38 am; edited 1 time in total
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kauboi
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PostPosted: Mon Nov 10, 2014 1:20 pm    Post subject: Reply with quote

Awesome project, Im curious how the electronics part will be worked out, did the parts include an ecm?
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Zeitgeist 13
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PostPosted: Mon Nov 10, 2014 4:09 pm    Post subject: Reply with quote

Sweet build!
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snowsyncro
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PostPosted: Mon Nov 10, 2014 4:19 pm    Post subject: Reply with quote

Looking forward to this!

RonC
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RollingDutchman
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PostPosted: Mon Nov 10, 2014 6:16 pm    Post subject: Reply with quote

If my VR6 ever goes I want something like this. I'll be watching this one!
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Itsamoto
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PostPosted: Mon Nov 10, 2014 7:33 pm    Post subject: Reply with quote

Right on! Kudos to you for sharing this -- I'm sure that lots of EV owners want to see this conversion.
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gresh125
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PostPosted: Mon Nov 10, 2014 10:32 pm    Post subject: progress Reply with quote

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pulling the old pedal assy proved to be difficult. putting the new one it was even harder but was a direct bolt in, had to remove some brackets that held the throttle potentiometer in place. and also unbolt steering column to wiggle it up in there.
as you can see on the fire wall side I left the original master cyl floating there by brake lines. it bolted right to the new booster no problem.

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Of all of the wiring there was a couple of main harnesses that came with the tdi. only needed the ecu/engine control harness. the others were to control cooling fans and lighting and such. I just kept my original harnesses from my 02' on board for cooling fans and lighting. these connection shown in pic are the only ones needed to control and monitor engine. now to route these through the dash and see if there is a place to plug em in.
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Xtremjeepn
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PostPosted: Tue Nov 11, 2014 11:36 am    Post subject: Reply with quote

I'm actually about to start on this conversion myself. Wink Picking up the Eurovan its going to probably go into in a few days.
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gresh125
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PostPosted: Tue Nov 11, 2014 7:49 pm    Post subject: wiring blues Reply with quote

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I hung the engine right near a I could to do testing before final bolt in.
routed the wires through the fire wall and removed old ones.

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yes the package did include an ecm and it bolted right up.

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all of the new connections plugged right in both behind the fuse panel and the individual connections. they are all color coded plugs and even the wires are the same color so I wont go into detail on those Im just hoping it works.

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I pulled my little kubota up close and used its fuel tank and pump to feed the 2.5 some diesel.
It cranked but nothing. I put a jumper wire from + to the fuel solenoid on the injection pump. and tried again and it ran for about 2 seconds.
ok so I know the engine is good.
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Xtremjeepn
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PostPosted: Tue Nov 11, 2014 7:52 pm    Post subject: Reply with quote

Sweet!
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gresh125
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PostPosted: Tue Nov 11, 2014 8:22 pm    Post subject: more wiring woes Reply with quote

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ok so even after all the new connections and plugs from the tdi engine seemed to find there home under the dash, there was still extra wires/ connections that now dont have a mate. maybe more acc that ran to the vr6 before I went crazy under the dash. take my advice here take your time with wiring and try not to cut anything even if you think it is running to the auto trans and you think Ill never need those.

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if you are going to do a swap these are a must. I found mine here on the samba from a nice gentleman. for 90 shipped . also get the vcds software and comm cable to talk with you vw.

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plugged mine in to see whats going on, or should I say whats not going on.
heres what I got. I am going to have to systematically check each wire on the dash side that has no mate and find its home or make a home for it. once that is done I will see if vcds will talk with ecm.
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Last edited by gresh125 on Sat Nov 15, 2014 1:55 am; edited 2 times in total
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kauboi
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PostPosted: Tue Nov 11, 2014 8:40 pm    Post subject: Reply with quote

That's super cool about the wiring being so easy, and the ecm just plugging right in. How are the axles as far as lengths and sizes of the inner and outer cv's and splines?
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shadetreetim
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PostPosted: Tue Nov 11, 2014 8:56 pm    Post subject: Reply with quote

Cool project.
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gresh125
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PostPosted: Tue Nov 11, 2014 10:16 pm    Post subject: ecm/axels Reply with quote

Just so I didn't confuse anyone. The harness that came with the tdi is complete with ecm plugged into it, I never removed it. so the complete vr6 engine harness isn't be used at all. as for the axles they came with the package and are slightly different lengths. the splines on the wheel side are the same. this whole package is a direct bolt in.

If I cant sort out the wiring, I found a guy in the Uk that will turn my pump into an all mechanical pump. m-tdi
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Itsamoto
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PostPosted: Wed Nov 12, 2014 2:05 am    Post subject: Reply with quote

Do you need to change out your cluster for this to work?

http://www.vwt4forum.co.uk/showthread.php?t=86937
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kernewek
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PostPosted: Wed Nov 12, 2014 5:12 am    Post subject: Reply with quote

Excellent project, and I know already you'll be please with the result. Which code motor did you purchase? ACV, AJT??

If you need any under hood detail pics let me know.

Craig
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Gruppe B
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PostPosted: Thu Nov 13, 2014 12:17 am    Post subject: Reply with quote

Here is a link to a 2.5tdi for sale in canada
http://www.kijiji.ca/v-engines-and-engine-parts/wi...nFlag=true
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gresh125
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PostPosted: Fri Nov 14, 2014 2:41 pm    Post subject: good stuff Reply with quote

Thanks for the write up on the clusters great info. and the code on the engine is acv.

A little update for you folks.
I seem to be lacking vital wiring diagrams in the bently manual.
no missing pages though. I have been digging alot and found this web site.
great free diagrams but unfortunately not for my year range of engine.

http://www.vwbooks.co.uk/t4.htm

but through all of that digging and reading in my benty the reason I have no power to my ecu is because I am missing relay 3 voltage supply to ecm, and relay 12 glow plug relay. relay 12 on the vr6 originally was for fuel pump in tank. glow plug relay location 12 is to be a #103.
and ecm power relay location 3 should be a #109. may borrow those two from my golf tdi later today. seem to me the best way to get these relays is on line as the auto stores are confused and have 3 different choices on glow plug relay but they dont understand what 109 or 103 is. and dealer will be priced to high.
going rate about 12 buck a piece ebay and other places.

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yellow arrow position 3 req a #109 relay
red arrow position 12 req a #103 relay. my golf only had a 109 relay so I borrowed that for now.

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as per the book 97 2.5tdi

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Timing belt arrived today my son seem happier than me ha.
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Last edited by gresh125 on Sat Nov 15, 2014 1:46 am; edited 1 time in total
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gresh125
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PostPosted: Sat Nov 15, 2014 1:22 am    Post subject: beutification Reply with quote

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got my timing belts installed. my kit came with all of the tensioners 2 belts and a water pump. seemed like a good time to change belts while the engine is out, though the old ones look decent. better safe than very sorry.
one belt drives the cam and the other drives the ip.
one of the allen bolts on the harmonic balancer stripped out on me so I welded a bolt onto the head of the allen and that twisted right off so I then welded an extra socket I had laying around to the head of the bolt or to a big blob mess of weld at this point and that held and it came right out.
I dont think I will be reusing this fastener.

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I spuced up the motor a bit with a little red paint.
and by the way it does indeed bolt right in. now back to wires .
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gresh125
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PostPosted: Thu Nov 20, 2014 7:26 pm    Post subject: update Reply with quote

I borrowed the ecm relay #109 from my golf and vcdc is now talking to the ecm . i then plugged in my kII ross tech plug and ran a check this is my results. my main concern right on top is start blocked by immobilizer. the rest of the faults are simple and can be remedied by plugging in the sensor that aren't plugged in yet i.e air temp, egr valve ect. any thoughts on how to get around the immobilizer .
i do believe the vans original immobilizer is behind the cluster on 02' ev's. not sure if the tdi ecm has one in it too. strange there is two different fault codes for the immobilizer.
getting closer folks. going to drop the tank soon ditch the hp fuel pump and modify filler neck to accept a diesel pump nozzle. more to come soon.
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