Vw tips

Tips and trick for PD 1.9tdi/1.8t swap

Photo gallery and information on how to build the clutch and starter.

Valeo 835026 +VAL438072/ 068911024H starter

The Val835026 is an aftermarket 240mm single mass conversion kit designed for the 1.9 TDI engine. You can modify the center splines of the clutch disc to fit the transmission shaft of your Mitsubishi, Suzuki, etc... and other vehicles. Additionally, the clutch friction material can be upgraded to a stronger level for improved performance and durability.

Starter modification

Note: You should use this starter with the previous VAL835026 clutch set. The swap also includes a starter cutting to ensure the pinion properly engages with the flywheel gearing teeth.

One mass 026105269L + 03G911023A starter

You can build your clutch on OE 026105269L one mass flywheel that could be find in Audi 80/100/A6 C4 1.6-2.0l models, on the vw engines with codes: 1Z,ABT,ABK,ACE,AHU etc.

It comes with a 228mm clutch disc from the factory, but it can be modified to accommodate a 240mm clutch disc.

This flywheel is thin and low. It is better for gearboxes with a smaller bellhousing (Suzuki, bmw e36, etc.)

Pressure plate:

You can use pressure plate from a VW LT Van with an ATA or AGK engine.

You can also redrill holes for BMW e34 M5 883082 999765 240mm or Vw 240MM 883082999707 sachs extreme pressure plate and use your clutch disc that fits on your transmission shaft.

Starter modification

Note: You should use this starter with the 026105269L flywheel. The swap also involves cutting the starter, allowing you to bolt it from the engine side. This modification means you don't have to remove the gearbox or engine to unscrew the starter, providing a significant convenience.

Note!

The VAL702072 flywheel (from val835026 set) is thicker than the 026105269L flywheel. The VAL702072 also requires a 8-10mm spacer between the crankshaft and flywheel due to the thickness of the swap adapter (please note, we do not offer this spacer at the moment).