How Far To Build Engine
« on: August 20, 2017, 02:29:06 PM »
Hey guys,

After years of thinking about this swap, I finally have a clear garage bay and have just purchased my donor, a 1997 Passat TDI. I have yet to get a response from Frans @ Dutch Auto despite emailing him twice. I hope he is well.

My question is this: How far should I build the engine before installing it into my van? I will, at the least, be doing top end work such as stem seals and maybe a cam, but I'd rather leave the bottom alone.

I assume that with head studs, I should be able to get away with a VNT17 (or similar). My main goal is not a hot rod, but a majority of my driving takes place in the NYC area, where stop and go is vital to survival. So I will most likely end up with bigger injectors, a larger turbo, and a tune.

On top of all this, I'm on a bit of a budget, and I'd like to avoid opening the can of worms that is the bottom end.

Van is a 2002 MV with a burnt up torque converter and toasted reverse clutches. Don't ask who did it ;)
1984 380SE, 1979 450SL, 2002 EV MV, 1988 325iX

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Offline andrew

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Re: How Far To Build Engine
« Reply #1 on: August 22, 2017, 12:07:25 PM »
You definitely want a VNT 17, and if your donor is a 1Z you want at least ALH pistons. If you're going to be flooring it a lot the bottom end will be under significant stress.

Get an EGT and manifold pressure gauge and watch for spikes and you'll be fine.

Re: How Far To Build Engine
« Reply #2 on: August 26, 2017, 03:40:04 PM »
Whoops, didn't have notifications on for this thread.

Is there a go to larger than stock non-VNT turbo that anyone has used in their vans? I'd need a different ECU to control the VNT, correct?

How do you think I would fare with just bigger nozzles, a Colt cam, head studs, and a tune? Will it be undriveable? The stock setup with 201hp/181ft lbs mated to an auto was more than plenty, and if you ex-5 cylinder guys only had 110, and that was comfortable, I'm sure the above mentioned mods would be fine.

I know a lot of this tech stuff belongs in the TDI Club forums, but I'd like to hear it from EuroVan guys.

Thanks so much.


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1984 380SE, 1979 450SL, 2002 EV MV, 1988 325iX

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Offline andrew

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Re: How Far To Build Engine
« Reply #3 on: August 27, 2017, 08:57:35 AM »
The 5 cyl gasser was undrivable, and I managed to get one that was running quite well.

Mine now has a VNT 17, 11mm pump and .205 nozzles, and I'm very happy with it. Just back from a road trip through the mountains and it consistently returned 30mpg. The gasser was 19-24 and the uphills were slow and loud.

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Offline filmshoot

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Re: How Far To Build Engine
« Reply #4 on: September 20, 2017, 09:56:57 AM »
I've got the 1z, 11mm, and top end work only with a 1722 turbo ...  I'm at 28k miles on this setup.   But definitely use the alh manifold gaskets,  and definitely use the most recent crank pulley

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