I am Depressed. This is not what I wanted, but at least now I know what is achievable.
Thank you very much for the knowledge, before I spend money on the project.

 

I just had a meeting with VW stealer guys and they say that they can build a Jetta TDI in mexico with 2.5l for $20,000.00 as 4X4.

Fishy .... is int it?

 

http://forums.vwvortex.com/showthread.php?4495286
http://forums.vwvortex.com/showthread.php?4401882

he says he used stock b5 tranny and a few other b5 accessories, im considering doing this, but im still debating if the cost will be worth it....

 

Crunch the numbers! It's pretty much never the economical thing to do...it just has to be something that you want to do.

It's fairly simple to swap engines in VW/Audis though – most of the engines from the same time periods bolt right in with the appropriate engine mounts. My block is from a VW Golf, and my head is from a '97 Passat. Notable points:

- Transmissions usually only bolt up to engines that have the same number of cylinders as the car the transmission was originally from, i.e., 4cyl engine bolts to 4cyl tranny, 6cyl engine bolts to 6cyl tranny. Gear ratios are something to consider as well.
- You need the engine management, and everything that goes with it, to match the engine, i.e., ECU, harness, cluster, sometimes pedal assembly.
- Driveshafts match the tranny; sometimes you'll need spindles to be able to run the driveshafts on the new chassis.

If you find a donor TDI car, you'll have everything you need to do the swap, but you might want to pick up a European B5 TDI cluster. There are some good swap threads on TDIclub.