Bears Sidekick 1Z TDI swap

[Karhu]

Ok here goes,

The goal is to swap full Golf 1.9Tdi 1z engine to Sidekick/Tracker, no M-Tdi but full TDI installation.
Thanks to Jeff at Acme Adapters, engine is in. Here's were I'm at....

Intercooler mounted and ducting done. The cooler is from -00 1.9TDI Passat. I modified the Suzuki radiator bracket , to mount the radiator and the intercooler. The radiator is from the doner Golf and the core size is 25x13". The radiator is mounted upside-down to get hose connections to the drivers side.





PS mounted. I used the orignal VW pump and alternator bracket and fabricated my own pump bracket. To get the correct belt offset I had to use the same pulley as in the water pump.




2.5" exhaust that runs down from the passenger side....


Air intake:

[ScotY]

That's a really nice, clean looking install!  Got any more pics?

What year Golf and any idea on how hard the wiring is going to be?

[Karhu]

The engine is from 1994 Golf III. The donor Golf was a good find since, there was no immo and the mileage was low. The best possible engine to swap would have been 1Z TDI engine from Audi 80, because the turbo is oriented the same way than in the AAZ engines. Also in Audi 80 engine the alternator is located in the passengers side and power steering unit is a direct fit to sidekick.  I have done a lot of wiring in the past, so I'm more worried about everything else.

The VW ECU will be mounted in the same place were stock ECU is.  Tooling that you need for the wiring:

- OBDII reader
- Pin extraction tool
- Contact crimp tool

I'm cosidering two options for the throttle drive-by-wire conversion:

1. Custom accelarator pedal bracket that houses VW gas pedal and sensor
2. The stock cable and gas pedal and the sensor mounted to the engine bay

Here's a link to the radiator that I'm using:
http://www.aaronradiator.co.uk/products/Radiator_VW_Golf_Mk3_94_99_1_9_TDi_2VW167-2700-1870.html

And the intercooler:
http://www.aaronradiator.co.uk/products/Intercooler_VW_Passat_Mk5_96_00_1_9_TDi_4AI112-5322-1622.html

Still looking for a good place for the diesel fuel filter and the VW coolant expansion tank......

[ScotY]

Cool, looking forward to an update. What kind of intercooler piping is that?  Looks nice...

[4wheeler]

What year Audi 80 has the turbo top mounted?
What Turbo does it use ?

[Karhu]

At least the one I have seen was 1993 1Z 1.9TDI and the turbo was garrett....

1Z 1.9TDI's were in Audi 80's 1993-1996.

Got the coolant expansion tank mounted;



The turbo ducting is made from silicone hoses and from 2" aluminium tube

[ScotY]

That ducting looks cool...kind of a spiral carbon wrap look to it. 

What is an Audi 80?  Is that a US model?  Sorry...I don't know much about Audis.  Would be nice to have other options as far as trying to locate a suitable donor.

[Karhu]

That ducting looks cool...kind of a spiral carbon wrap look to it. 

What is an Audi 80?  Is that a US model?  Sorry...I don't know much about Audis.  Would be nice to have other options as far as trying to locate a suitable donor.

I think that Audi 80's were not imported to US as a diesel..... So you might have to use vw golf 1z engine. In that case you need the oil filter bracket from a north-south installation and the thermostat head. Because of the turbo orientation you can not use ie. Acme alternator bracket.

[Karhu]

Got the radiator mounted and the fans. The radiator is from 1.9TDI Golf mounted upside down, since i needed to get the hoses to the drivers side.








The alternator is a Valeo 90A:



The gas pedal position sensor was easier install than I first tought. I simply made a bracket behind the oem gas pedal and moved the wire connection little bit lower to get the full travel in use.



I still need to find a position switch to the clutch and brake pedal. I will install them for 2 reasons.

1. I want Cruise Control, and this feature is intergrated to the 1Z ECM.
2. When the clutch or brake is pressed, the diesel feed is reduced ( Fuel Economy )

The TDI wiring seems to a hot topic, in my opinion it's not that difficult.  Yes it's more work, but the end result is worth it. Better fuel economy than in M-TDI and power band can be controlled by programming the ECM.

If some of you guys are looking for bracketry for ac it just might be possible to use Audi 80 combined alternator/AC bracket, since Audi mounted them to the passengers side. And I verified the turbo orientation and all the Audi 80 1.9 TDI's have the mounted upwards. Also the power steering pump looks like it is direct fit to Sidekick installation.  The oil filter bracket when used with Audi's own oil filter will clear the motor mounts and transmission.  If only I had know this a couple of months ago......

[RazorRodent]

Thats a thing of Beauty

[Nunya_Binnez]

Keep up the great work!

[Karhu]

OK, now the engine is up'n running. In the first trial I had 4 error codes, two of them I expected two i did not. The two were bad connections in the engine wiring harness, but when those were fixed the engine fired up right a way...  I will take some pictures as soon as I will get my fu..... I-phone back from service......

[mud and diesel]

Hi, Ive been dying for an update on this thread for ages, i was just realy curious as to what you did with the wiring. Im about to embark on the same conversion, ive got my hands on a seat ibiza with a vw ahu tdi motor (With a chipped ecu).
Im already running a acme converted vw1.9td so the mechanicals should be a straight swap, I was planning on taking the complete loom from the car (I mean everything) and fitting it to the vitara, just swapping plugs for accessories like electric windows, lights central locking, i was also going to fit the seat clocks to the vit dash, i could then have the rev counter, temp gauge, warning lights, etc I completely stripped the truck before to fit pre 98 dash and interior trim, and add central locking, electric windows so i dont mind a bit of wiring . Id love to here your views!
Pete

[Karhu]

I've been driving my conversion for a while now, and I seem to get 8l/100km diesel consumption no matter were I drive. At the moment I'm running stock R&P gears (5.12) and 205/75R15 tires. I haven't gotten around to swap the R&P gears to 4.3 yet and my 31" tires...

What i did with the wiring loom was that, i took apart Vitara's wiring loom and removed all the stock wiring going to the engine except the starter wire. You do not have to remove the wiring harness from the car, just peal the insulation tape off. You need to do the same to the stock VW engine wiring harness. Yes there should be only 1 wiring harness that is needed in order to make the engine run in Vitara, you do need the chassis harness.

You also can install the ECU from the AHU engine to same position than the stock Suzuki's ecu is. I placed all the new relays to the Suzuki's OEM relay plate underneath the ECU.

I would leave the Vit's chassis wiring intact, just add the wires from the Seat's engine wiring harness to Vit's wiring harness that you need + extra 2 x 6mm2 power cables for the engine heater relay and the glow plug relay. Once you have done this wrap the harness again with the insulation tape. It's easier to start making the harness from the ECU connectors side, and work your way from there to the engine.

If you want extra features like the clock in the dash, I would just modify the exciting Suzuki's dashboard wiring. You can get the Vit's tacho to work with Seat ECU RPM. You just have to swap a smaller resistor to the tachometers signal input. You can also use Vit's stock VSS output, to give a speed signal to the Seat's ECU. This means that you can add a cruise to your setup. Remove the immo from the Seat ECU if it has one, otherwise you have to use the Seat instrument cluster.

I have an excel sheet of the wiring and bracket templates (*.dwg) that you can use.....






 

[mud and diesel]

The excel would be a great help  , Im running 4.8 r&p with 31s and was averaging 35mpg with an AAZ, it was 30mpg on the 5.12's with 31s so your way under geared for a tdi . I have the old 8v box so the 5th gear is a shorter gear, its dead after 90k (40k diesel converted). Im going to get me a 16v box for the longer fifth im hoping to get 40mpg with 33"s, Ive also got a spare set of 4.3's but ill see how she pulls the 33s before swapping them out. Thanks for the pointers on the wiring too, saves me the hassle of trying to get the speedo to read right and hack up the dash.
Pete.