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Diesel Swap Tech and FAQ / AC RPM Compensation/Acceleration Cutout

« on: July 28, 2018, 11:40:37 am »

Looking for the TDI ECU and ClimaTronic to have a little more dialogue. More specifically, the hard acceleration compressor cutout and RPM/injection quantity compensation. The vehicle in question is a 2002 EVMV with a 1Z from a 1997 Passat.

Right now, I am left with two wires at the fusebox end of the harness:

-Brown/Blue, which is what I believe to be the cutout signal (assuming feeds 12v to some relay or the Clima head)
-Green, which is what I believe to be the RPM compensation (assuming looking for 12v when compressor is activated)

I'm guessing the original drivetrain had a similar setup, so two of the many disconnected connectors at the fuse box may be my ticket.

Has anyone else gotten this to work correctly?

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Shiny things you no longer want / Re: FREE Eurovan Head unit and CD changer

« on: February 27, 2018, 12:39:29 pm »

Thank YOU.

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Diesel Swap Tech and FAQ / Re: Some Wiring Questions

« on: February 24, 2018, 05:52:21 pm »

Came to the conclusion that the 2002 cluster recieves many of its signals through the Can Bus, and was probably not compatible at all with the 1Z harness.

I noticed I hadn't connected the long fused positive line to the alternator or the block ground near the transmission. I don't have the faintest idea as to why this happened, but I tried the B4 cluster again, and it worked fine. Instead of getting power from U1/4, it is getting it through KL15 at the top of the box. All fuctions are working as far as I can tell (engine hasn't been run yet), including the fuel sending unit.

I want to figure out a solution to the ABS and airbag lights. I am considering drilling out the two warning light blanks on the cluster and adding matching LEDs, but I'm not sure if the warning signal is over CAN or not.

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Diesel Swap Tech and FAQ / Re: Some Wiring Questions

« on: February 19, 2018, 03:09:32 pm »

I still haven't found anything that could have caused the burned segment. For the record, it was Pin 7 on the blue 32 pin cluster connector, which is U2/13, the "sender ground" or gauge ground. Cluster was working fine with the VR.

The burned segment is on the back of the cluster board and only heated up a section of the back segment, despite there being other segments throughout the board on both sides.

Also for the record: The only things that worked on the cluster were the two LCD displays (and the smoke machine). Not a single light came on, nor did any of the gauges move. Not a millimeter.

I've been at diagnosing this for over a week and haven't found a single thing amiss.

Anyone on here running a blue cluster in their 1Z or AHU conversion? Thanks.

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Diesel Swap Tech and FAQ / Some Wiring Questions

« on: February 10, 2018, 11:42:06 am »

Alright... I'm working on the last bits of wiring for my 1Z swap in my 02 MV, and a few confusing challenges have arised.

Firstly, I'm trying to get power to my cluster. I was really excited to use the B4 cluster for this swap, for both the looks and simplicity. E/2 and D/8 are both jumpered at KL15 at the top of the fusebox, and U2/1 has been relocated to U1/4.

With ignition off, the LCDs are on, but they die once ignition is on. I even took U2/1, added a single connector to it, and plugged it directly into KL15, which I know for a fact is getting 12v with ignition on. Still a dead cluster. I unplugged E/2 from KL15 and plugged the VR6 cluster back in.

The LCDs worked with the ignition on and off, but I ended up burning a large segment of the circut board, and I'm still trying to find the reason for that. I couldn't get the backlight to work either. Crossing my fingers I haven't burnt up two clusters at this point.

Secondly, I'm having an issue with my brake lights. Originally, an 02 EV uses the MK4-style 4-pin brake pedal switch, in which I cannot find the original connector for (I believe it's on the VR6 harness). I used pins E/3 and 4 with the Passat's switch and connector, but I'm still not getting anything.

Hopefully you see this, Justin! Any advice is greatly appreciated!

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Diesel Swap Tech and FAQ / Re: Adapting VR6 Air Box to TDI MAF Sensor

« on: December 29, 2017, 07:05:28 pm »

A reply from the king of T4 TDI swaps himself! What a surprise.

I'll give that a try tomorrow. Thanks for the reply.

Another question while we're on the topic of air management: Have you used the 2.5TDI intercooler on any of your swaps? I just ordered one with the mounts and hoses. My 2002 looks to have provisions for mounting.

And a happy new year to you as well.


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Diesel Swap Tech and FAQ / Adapting VR6 Air Box to TDI MAF Sensor

« on: December 29, 2017, 06:31:15 pm »

Curious as to how others retained the stock VR6 airbox in their TDI swaps. The MAF seems to bolt right up to where the VR6 MAF was, but there is a huge difference in size. Trying to make this look as clean as possible.

Thanks guys.

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Shiny things you no longer want / Re: Eurovan Sinka/Dokas

« on: December 29, 2017, 04:32:50 pm »

That's awesome. I guess this is why I've been having to wait so long for Frans to respond.

These would all make great TDI candidates, given the basic ancillaries are already in place.

Really, really awesome what you did. I'm sure I'll see at least one parked in Brooklyn in the next few years...


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Diesel Swap Tech and FAQ / B4 Cluster in 2000+ EuroVan

« on: September 19, 2017, 09:35:33 am »

After freaking out about cluster wiring for a month or so, I decided to pull my B4 cluster and see if I could even fit it in my EuroVan, as everyone says they don't fit in 2000+ models.

Well, they do. I put it in the dash and the fastener holes lined up perfectly. I think the only modification would be to get an earlier cluster surround. I popped my surround on, and with the steering column cover, there is just a small gap at the bottom of the cluster. Not a huge deal.

The other thing to consider is keeping the interior lighting scheme consistent. The B4 has the "green" scheme while the MK4 has "blue/red". I personally prefer the look of the B4 cluster, so I'm sticking with it.



I hope this helps 2000+ owners!

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Diesel Swap Tech and FAQ / Re: How Far To Build Engine

« 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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Diesel Swap Tech and FAQ / 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

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Diesel Swap Tech and FAQ / Re: 2002 EV MV TDI Swap questions

« on: February 17, 2016, 07:58:35 pm »

Thanks for the response! Yeah, I don't see too many long-nose swaps, but it's probably very similar besides a few VR6 things.

Thanks for all that info as well!!! I actually used to mess around with Arduinos in middle school (a few years ago), so I'm a little familiar with the code.

So would the ABL cover work for the AHU? I heard all these old style TDIs are similar block-wise.

Your writeup is definitely going to be helpful. Thanks again! I'm off to go polish some Mercedes valves and dream of TDI EuroVans

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Diesel Swap Tech and FAQ / 2002 EV MV TDI Swap questions

« on: February 17, 2016, 07:16:27 am »

Hey guys,

I'm looking to convert my 2002 24v VR6 EV to TDI. I want this swap to be easy and quick. From what I have read, it's not too hard. I've never swapped an engine, but I consider myself somewhat experienced as I am in the middle of a top end rebuild on my Benz V8 and I've pulled the top timing cover off my van before. I guess you can say that I've been "in there" before. I'm also parting out a MK3 Jetta, so I'm somewhat familiar with the components of a MK3 if I opt to use one as a donor car for the swap.

I have a couple of questions...

Would I be okay with just the following parts?

-MK3 Jetta TDI (donor)
-EWB transmission with linkage, clutch components, and mounts
-T4 pan
-T4 dipstick
-T4 pickup
-T4 AHU mounts


How much "custom" work is involved with this swap in terms of drilling the block, custom mounts, and other stuff?

Is the wiring really THAT hard on this swap?

Can I retain ClimaTronic as well and still be able to read it with VAG COM?

Can I retain my ABS if the donor MK3 doesn't have it?

Will it be hard to fit the MK3 cluster into the EV?

Since my EuroVan has a lot of MK4 components, would an ALH swap be wise, or should I still stick with the AHU swap?


I spoke with someone from Dutch Auto Parts (I think Frans), and the prices are very reasonable for what I would need.


Thanks guys!