Caddy BJB to ASZ Conversion

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Bumblebee58627
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Caddy BJB to ASZ Conversion

Post by Bumblebee58627 » Sun Apr 15, 2018 9:47 am

Guys just want to know when doing BJB to ASZ swap, are there any other things that will have to be done?
Is it a straight swap.?

I will do stage 2 software, i already have a decat down pipe and straight pipe exhaust.

Im considering this swap because i feel the ASZ is stronger and more reliable than BJB.
Last edited by Bumblebee58627 on Sun Apr 15, 2018 9:47 am, edited 1 time in total.
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Re: Caddy BJB to ASZ Conversion

Post by VGTI » Tue Apr 17, 2018 9:53 am

Where do you get a low milage ASZ?
'04 Polo TDI 1661.9 km on 58.05l
'13 Hyundai Santa Fe 2.2 Elite
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Re: Caddy BJB to ASZ Conversion

Post by Bumblebee58627 » Tue Apr 17, 2018 10:52 am

Okay maybe not low mileage, but if you work out 8k for injectors 7k for turbo, there is complete asz engines on Gumtree for around 17k. So i can buy a complete motor with the same amount as buying a turbo and injectors.

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Re: Caddy BJB to ASZ Conversion

Post by Bumblebee58627 » Sat Jul 28, 2018 8:44 am

Bumping the post... I am saving money for the conversion, but i need info on the swap?

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Re: Caddy BJB to ASZ Conversion

Post by Ashveer03 » Sat Jul 28, 2018 9:50 am

I doubt anybody has done this swap..
I dont have any experience on a BJB engine either.

Since the bjb is also a transverse pd engine, the mounting point should be the same as the asz..
All the wiring and piping should also be plug n play, u will need a remap though.

The problem u might have is with the clutch assembly (i assume the bjb is a 5speed).
Asz is mated with a 6speed gearbox which uses a 240mm clutch.

I guess u would need to lookout for:
1. If the 6speed clutch plate splines fit the 5spd spigod shaft
2. If the 240mm flywheel fits the 5spd bellhousing
3. If the 5spd starter engages correctly on the 6spd flywheel
4. The clutch concentric might be a problem..?

If all that works out (i doubt it would) then u should be good.
If not, then u either have to use a 5 speed clutch and flywheel (i guess a smaller clutch will wear out prematurely if u plan to modify), or get a 6speed gearbox, driveshafts etc

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Re: Caddy BJB to ASZ Conversion

Post by Bumblebee58627 » Sun Jul 29, 2018 1:24 pm

Ashveer03 wrote:I doubt anybody has done this swap..
I dont have any experience on a BJB engine either.

Since the bjb is also a transverse pd engine, the mounting point should be the same as the asz..
All the wiring and piping should also be plug n play, u will need a remap though.

The problem u might have is with the clutch assembly (i assume the bjb is a 5speed).
Asz is mated with a 6speed gearbox which uses a 240mm clutch.

I guess u would need to lookout for:
1. If the 6speed clutch plate splines fit the 5spd spigod shaft
2. If the 240mm flywheel fits the 5spd bellhousing
3. If the 5spd starter engages correctly on the 6spd flywheel
4. The clutch concentric might be a problem..?

If all that works out (i doubt it would) then u should be good.
If not, then u either have to use a 5 speed clutch and flywheel (i guess a smaller clutch will wear out prematurely if u plan to modify), or get a 6speed gearbox, driveshafts etc

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Thank you.

I am planning to do a stage 2 tune once i do the swap. I have downpipe and straight through exhaust already.

I am also replacing the clutch and flywheel to a single mass and performance clutch.

The bjb is basically the same as the bls.

I was just hoping the piping and wiring are straight forward.

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Re: Caddy BJB to ASZ Conversion

Post by More_boost » Mon Jul 30, 2018 9:08 pm

You are going to run into issues on the crank sensor
Mk5 based 1.9tdi’s are slightly different to the Polo/Cupra based 1.9tdis

Crank sensor on the BJB motor is located on the rear main seal and the ASZ is located to the right of the oil filter housing/cooler

They use different sensors


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Re: Caddy BJB to ASZ Conversion

Post by Ashveer03 » Mon Jul 30, 2018 10:08 pm

http://www.vwcaddy.com/showthread.php?8 ... ion-PD-TDI

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Re: Caddy BJB to ASZ Conversion

Post by Bumblebee58627 » Wed Aug 08, 2018 8:17 pm

Ashveer03 wrote:http://www.vwcaddy.com/showthread.php?8 ... ion-PD-TDI

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Thank you Ashveer03, that's actually a really helpful thread.

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Re: Caddy BJB to ASZ Conversion

Post by Ashveer03 » Wed Aug 08, 2018 11:24 pm

Cool.. now u know whats to be done and whether u want to do it.. lol

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Re: Caddy BJB to ASZ Conversion

Post by shanky887614 » Thu Aug 16, 2018 2:23 pm

a bjb to asz swap is very easy.


the 5sp from the bjb bolts straight to the asz or you can use golf mk5 2.0tdi driveshafts.


you need to buy a new crank seal for the bjb and fit it to the asz and drill the webbing off the block so you can mount the sensor.


very easy and popular swap in the uk
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Re: Caddy BJB to ASZ Conversion

Post by Bumblebee58627 » Fri Oct 05, 2018 3:44 pm

So my BJB finally gave in. I am going to attempt to do this swap in the next few weeks. I will keep everyone posted, if it works or not.

I am collecting the ASZ engine tomorrow. :crazy:
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