I recently completed the swap of an AHU tdi from a '97 Passat into my '93 Weekender. I used a Kerma Stage 1 chipset and blueprinted DLC1019 nozzles, but the 200k-mile engine is otherwise stock. I also used a South Bend Stage I clutch setup to handle the purported 150 hp and 300 ft/lbs torque, and the pedal feels like a stock unit. I started out swapping the 0.756 fifth gear from the Passat transaxle into my 02B CHP-geared trans, but it was still way too low -- had to shift to second gear just to make it through an intersection, and it revved at ~3300 rpm at 70 mph. Ended up getting an EWB-geared trans from Frans in the Netherlands (
info@dutchautoparts.com) shipped to my door for ~$1400 and it is now perfect. I had to get my vehicle through CA smog testing, so modifying intake system and cat/downtube were probably the greatest challenges. I love my van (have about 5k miles on the conversion now), though it needs some bodywork and paint to make it perfect. Good luck with your project!
Geoff
SLO, CA