VW T25 from 2.1 Petrol to TDI

Start to finish of converting and 2.1 MV engined T3 to to a 2001 ALH TDI VW Golf engine.

[@mikehodson4911]

great vid, thanks

[@westfaliawanderings]

I did a TDI swap on my 1.6 TD 5 speed '88 camper but I used an AHU TDI. Some of the issues were similar with the swap you did, but having my new engine share the familial engine block geometry with the 1.6 really reduced the fabrication necessary. I am very happy with the results as the van is so much better to drive.

[@TheTinski07]

I have an AHU in my own van. Great engine and a bit easier to wire up. Mine was a 1.9DG so I had to make all the mounts etc and used a flipped Audi gearbox

[@westfaliawanderings]

Most of my install was straight forward (including using my existing 5 speed gearbox, a Corrado flywheel, and latter water boxer clutch disk) but I ended up using the original JX turbo and exhaust manifold so I could keep my relatively new stainless exhaust.. The turbo failed soon after and that started a series of issues I have had with the install. The biggest problem I have had has been with oil pumps and getting enough pressure and flow to supply the turbo, bearings and also the lifters. Long story in short, after a couple of engine and turbo fails I now have a fully rebuilt engine with the physically larger VW oil pump and that seems to have solved things. The van now runs great.

[@roughengineering3673]

Brilliant video thank you

[@pyronitro]

all that wiring is good stuff and i'm glad you are mentioning it. i actually wish you have more! The wiring is what makes the ALH/PD plus the possibility of ECU mods for better economy or power. i'm planning to put in the ALH speedo cluster in in my conversion. still wondering whats involved with wiring it.

[@TheTinski07]

The cluster is required to if you keep the immobiliser as it is part of it. The next one I do I will not be using the key/transponder or cluster to make a cleaner install. Unlocked ecus are cheap on evay for alh/pd engines. To install a cluster you just need the pin outs for the green and blue plugs and a wiring diagram. The loom from inside the car isn't required. I have a 130 PD inbound soon may do a full wire up video of that on the ground in a few months time

[@pyronitro]

@@TheTinski07 i would like to keep it to add a layer of security. it gets stolen here all the time.

[@davewernham5623]

Fantastic videos and content ….👌👌👌

[@jaimetellez5246]

Could you please let me know the name of company where you purchased the oil pick up extension adapter. (Something engineer) I couldn't understand what you said on video. Thank you!

[@TheTinski07]

Ultimate engineering in the UK produce the sump adapter and oil pick up adapter. The pick up tube required is from an audi or passat with a longitudinal engine configuration. I bought that separately but Tim Shettle at ultimate engineering might have those too.

[@jaimetellez5246]

I have a t3 with a jetta 2.0 aba engine swap and it has that same oil pan your engine has. Does that oil pan changes the oil capasity.

[@TheTinski07]

I ran it with 4.5ltrs as standard. Ultimate engineering's page had a photo of a cut sump showing it with the adapter and pick up. Best to look at that if you were interested to see how close to the pan base it sits. I did use the baffle type sump gasket and I'd have no concerns with it really.

[@wonkylommiter6364]

With the turbo sitting so low with this conversion, are there any problems with the oil return from the turbo being less than ideal? the return pipe looks pretty much horizontal on some conversions I've seen, Thanks

[@TheTinski07]

It doesn't seem to be the case. A lot of people are even using the the original oil return which is higher up but then it is at least above the oil level in the sump. The oil return low in the sump isn't exactly optimum either but it seems vw were happy with it. I would still rather return to the sump than the block.

[@eoincooney2565]

Please explain the fitting of the golf TDI flywheel to a standard diesel T25 gearbox in a bit more detail? You mentioned having to do some grinding?

[@TheTinski07]

There is nothing much really. It will touch the inside of the bell housing in one or 2 places and it's just a case of giving those areas a light rub of the grinder. It would be better practice to use a dual mass flywheel for the sake of the gearbox

[@CharlieandMeOurCampingVlog]

do you have any half done T25's for sale ?

[@TheTinski07]

I have an air-cooled one that I haven't started work on yet but has a slot to get done.

[@CharlieandMeOurCampingVlog]

@@TheTinski07 ok thanks for getting back to me im looking for one as a camper project that i will mainly have to build the inside welding isnt my thing

[@roughengineering3673]

@@CharlieandMeOurCampingVlog I've one here might suit you