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Yellow Van to TDI conversion

This was Crsmp5 (burnt toast) original idea, I thought I should promote it to it's own forum as it is has been so popular.

Yellow Van to TDI conversion

Postby luckham » Sat Apr 30, 2016 11:19 am

Another conversion project underway, just pressure washed everything and now about to pull the engine from the donor.
jetta and yellow Van.jpg
Meet and greet

1998 Jetta TDI
jetta and yellow Van donor.jpg
The donor car with the engine ready to pull

jetta and yellow Van engine bay.jpg
The engine bay of the Kubvan
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Re: Yellow Van to TDI conversion

Postby shortysclimbin » Thu May 05, 2016 6:49 am

looking good. I have been tracking the progress on facebook videos. Please post pics up of the transmission swap. I really want to see how people are doing these and if anyone attempts awd status :P..
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Re: Yellow Van to TDI conversion

Postby CRSMP5 » Sun May 08, 2016 7:24 am

So you doing full e conversion or keeping it simple with a rover 300 pump you can get from the uko2a/o2a tranny swap easy... Mod set of rocco 100mm axles by grinding tbe lip off, only min or two with dremal.. Per side... Then i set clutch master on the inside using mitsu remote fluid bottle... Since lotsa room under dash...

People sell tranny mounts... His hardest items is downpipe... And ic placement...

Fyi ive blown 2 of those turbos... Both from overspool... Wipes oil seal pretty easy...
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Re: Yellow Van to TDI conversion

Postby luckham » Sun May 08, 2016 9:04 pm

I did the full e conversion, it went quite well once I labeled all the connections, studied the wiring diagram in the Bentley Manual and figured out what wires were simply not needed.
DBW set up.jpg

I did cheat with the tranny and stuck with the 020, I did not want to deal with the cable shift, mounting and the clutch details on top of the engine.
Good idea for grinding off the lip on the axles I will keep that in mind next time I do a tranny swap.
The down pipe is a pain, I have something that works for the short term but it is going to have to go to a shop to get it bent just right.
downpipe.jpg

I still have to play with the shift linkages, it will not go into 2nd or 4th because the lever bangs in to the down pipe. I think I can just shorten the link arm.
Lots of tidy up to do.
Plumbing details.jpg
wiring mess.jpg

I wonder if the over spooling is managed by the computer and it throttles back based on turbo boost measurement ?
Triplets SM.jpg

It's all new to me, lots more power that's for sure.
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Re: Yellow Van to TDI conversion

Postby luckham » Sun May 08, 2016 9:11 pm

shortysclimbin wrote:looking good. I have been tracking the progress on facebook videos. Please post pics up of the transmission swap. I really want to see how people are doing these and if anyone attempts awd status :P..


I blew it on photos of the transmission swap, that said I took the easy way out and used the 020 transmission.
The only gotcha was having to change the fly wheel and clutch, I should have thought that through a bit more, but it went smoothly.
The only problem is the down pipe it is in the way of the 2nd and 4th gear linkage lever. I an going to try an shorten it up, it should work.
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Re: Yellow Van to TDI conversion

Postby luckham » Mon May 23, 2016 11:32 pm

Finally done. Just posted some wiring diagrams in the engine section :
viewtopic.php?f=5&t=2656
Here is a picture of the finished install. 90 HP pretty snappy little van now.
Yellow Van Done.jpg


I will be posting more concluding remarks later. Gotta catch up with other neglected stuff in the mean time.
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Re: Yellow Van to TDI conversion

Postby luckham » Tue May 24, 2016 7:42 pm


Finally ready for prime time
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