ALH in to a Eurovan T4

archemitis

Veteran Member
Joined
Nov 16, 2012
Location
minnesota
TDI
200 Golf, 1974 Westfalia TDI
About 8 months ago I purchased a 1993 Westfalia Eurovan with 278k miles on it. It still runs and drives great, but I dont feel safe driving it across the state, let alone the country, so I decided to do a Diesel swap before I even bought it. Its been a few month of collecting parts, and a whole lot of reading and asking questions, but I have finally started making real progress. The ALH was never bolted into a T4 (as far as I can tell) so there is no VW example to copy.

First off the ALH bolted to the Eurovan 5 speed transmission. It does fit!



The original oil pan prevented them from bolting together because of the lower bell housing mounts. I also tried a hybrid oil pan. After my hundred dollar experiment I realized I had clearance issues at the CV extension on the transmission. I ordered an all steel pan and it bolted right on. There is still very minimal clearance for the CV



The Original IDI engine that this transmission came bolted to has a steel oil pan with no lower bell housing mounts. The tranny bolts to the engine with just 4 bolts. the top two and the two on the dowel pins. At first I was unsure about using a steel pan because of the rigidity of the engine to tranny mount, but VW did it from the factory with only 25 or so less horse power, so I should be cool.



The metal plate from the IDI Eurovan engine fills this gap.



This piece has to be modified. The rear main seal is a little different between the ALH and the AAZ so I will grind out the center where the bolts go into the block, leaving it sandwiched between the tranny and block with the 4 large bell housing bolts holding it.



The oil pan and oil pickup is the crux of this project, but I think the steel one is the key. You can see the Eurovan angle is completely different from the golf.



So the oil drain plug is at the high point of the pan. I have a steel weld in drain plug kit on its way to put it in the correct location. I think the oil pickup will be fine, and the dipstick may have to be remarked.

The turbos I have to work with are both wastegate turbos. One is a KKK, from an AGR that I have ran on this engine before.





And the other turbo is from the AAZ style engine that came in the Eurovan.



Im pretty sure Im going to run the turbo that is already bolted to the ALH unless I run into clearance issues when I go to installing the lump.

Other than that I really only have to make a motor mount for the passenger side and I have a plan for that using the stock ALH engine mount.
The 5th speed cover unbolts just like a golf so I am going to put a 5th gear more suited to the ALH sweet spot. I have already ruled out a 6 speed, or a 6 speed conversion.



The stock ALH golf clutch and G60 flywheel fit. SO I ordered a south bend stage 2 for a MK4 golf with an AHL.


Other than that I have 1019 nozzles, Stage 3 Rocketchip Tune, a big front mount, and a 3 inch exhaust.


Im happy it has bolted all together like the internet said it would. Its always scary to spend a big chunk of money without knowing for sure it all fits. I hope I havent forgotten anything and I would appreciate any feedback yall have. I appreciate all the help many of you have offered me to get me this far.
Its just got cold again up here in Minnesota, so HOPEFULLY I will get to installing it very soon, with more pictures and questions to come!
 

2many diesels

Veteran Member
Joined
Mar 20, 2011
Location
Nor Cal
TDI
rabbit pickup 1z swap Audi A4 Quattro ALH. 02 Beetle TDI. 99 Golf TDI. 03 Wagon TDI. 914 Porsche ALH t
Just bought a Eurovan yesterday for a swap. Trying to decide which motor to use....1Z...ALH...Yea, oil pan is an issue with the ALH. I do have a couple of the steel pans.
Was trolling youtube last night and saw a Eurovan with a PD motor in it. Might that be a factory aluminum pan that will work with our application?
 

archemitis

Veteran Member
Joined
Nov 16, 2012
Location
minnesota
TDI
200 Golf, 1974 Westfalia TDI
Yes, there are (in theory) some oil pans that VW made that are supposed to fit... The T5 with a 4 cylinder TDI. Theres a guy that is rumored to have a kit. I decided to use what was available in the US. Theres a guy in Portugal that installed an ALH actually an AGR, same thing only different turbo.
HE said "The pickup tube and the sump are from the AXB. It's not prefect since I can't use the oil plug to change the oil, because of the angle, but it's bigger and can take more oil. I also had to cut a bit of the sump near the gearbox Bellhousing."

1z and AHU would bolt right in. The ALH fits, just a little more work. No big deal compared to other vehicles.
 

Josh_WA

Veteran Member
Joined
May 8, 2015
Location
Mountlake Terrace WA
TDI
2014 Jetta TDI, 1993 Eurovan Weekender TDI(AHU) converted 2/2016, 93 Eurovan MV TDI(1z)(sold!)
Nice to see your conversion is happening with the ALH. I'm eager to see how your intercooler setup goes. I'm still floating my AHU intercooler above the engine. Also interested to see what you do in regards to the dipstick. Nice work.
 

turbodo

New member
Joined
Sep 17, 2017
Location
Duisburg germany
TDI
T4- Eurovan 1.9 ABL
Hallo i am frome germany. i got an ASV TDI Polo Variant. Try also to put it into my eurovan (T4) 1.9 TD ABL . Can you tell me how you have fix with the cable issue `?
and i got also the gear box 02J with cable , i tried to put it also into the eurovan ,but i think it is not going to be easy.
regards
 

jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
i would definitely rethink the oil pickup tube, it's slightly angled rearward to accomodate the 15 degree rear lean of an alh... you're now rolling the engine forward around 30 degrees so the pickup will now be pointing away from the oil supply ... Frans is now making a kit for T4 alh conversions and he supplies a new pickup to go along with the modified ALH pan
 

archemitis

Veteran Member
Joined
Nov 16, 2012
Location
minnesota
TDI
200 Golf, 1974 Westfalia TDI
Its in and driving.
Oil pan ended up being a generic stamped steel pan. It doesnt have the bell housing bolts, and extra ribs and casting that got in the way with the aluminum pan.
I cut and welded the oil pickup tube to point towards the ground instead of the rear of the vehicle.
Lengthened my original dipstick tube from the golf, welded on about 8 more inches to the stick and remarked it... lengthened the tube to ease checking it.
Used the original eurovan 4 cylinder engine mount, just had to weld on two tabs, and drill two holes...

Really alot of easy things to accomplish without expensive parts from some importer guy that doesnt tell you what hes sending you off of what car.
Im a big fan of making things work myself.

As far as my experience just told me, anybody could put an ALH into the Eurovan. Not as scary as some people make it seem... Just jump in there and start trying stuff.

Pics to come....
Just dont buy mystery parts from some guy that tells you its the only way to do it. =]
 

Josh_WA

Veteran Member
Joined
May 8, 2015
Location
Mountlake Terrace WA
TDI
2014 Jetta TDI, 1993 Eurovan Weekender TDI(AHU) converted 2/2016, 93 Eurovan MV TDI(1z)(sold!)
Cool. I wondering also if you are able to still fit the belly pan. I had to modify mine for the AHU I put in because of how low the power steering pump sits. With that, did the power steering high pressure side reach or did you need to extend it? What did you go with on the 5th gear ratio?
 

iwannajettatdi

Veteran Member
Joined
Jun 17, 2003
Location
Salem, OR
TDI
2015 Brilliant Black Audi Q5 3.0TDI, 2014 Tempest Blue metallic Jetta Sportwagen TDI, 2002 Blue Eurovan Weekender BHW TDI
Cool. I wondering also if you are able to still fit the belly pan. I had to modify mine for the AHU I put in because of how low the power steering pump sits. With that, did the power steering high pressure side reach or did you need to extend it?
Instead of keeping the PS pump and the pulley that is so low I removed mine and had a new PS pump high pressure line made to fit a mini cooper PSP and mounted it as a stand alone EHPS pump. Should be interesting to see how it works.

I haven't messed with 5th gear yet. We'll see which one I want to go for, I'm thinking at least .681, but likely .652 and theres a .62 or lower floating around somewhere with Darkside Development.
 

archemitis

Veteran Member
Joined
Nov 16, 2012
Location
minnesota
TDI
200 Golf, 1974 Westfalia TDI
<a href="http://s67.photobucket.com/user/archemitis/media/Eurovan%20TDI/IMG_20170225_090943889_zps6v9pocti.jpg.html" target="_blank"><img src="http://i67.photobucket.9pocti.jpg"/></a>

Heres where I started, It was a 4 cylinder mount from the IDI that came in the Eurovan. I used the original center hole, which matched the IDI and the ALH. I ended up adding an ear to the top to match another previous existing hole on the ALH. It worked pretty well. Ill see if i got a got pic of it completed. I got kinda hasty with taking photos, and forgot a few things.

I dont have AC or PS! :eek: Im just going to use the excuse that I am looking for the ultimate MPG.

The injection pump and oil filter are close to the stock fans on the short nose van, but they do not touch, even when the engine is rocking around.

I went .622 on the 5th gear.
 
Last edited:

archemitis

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Joined
Nov 16, 2012
Location
minnesota
TDI
200 Golf, 1974 Westfalia TDI
Also... big FMIC! Also, I gotta find the pic of the 3 inch exhaust, Including downpipe! It barely fit.



I also used the stock eurovan turbo, as it was a little bigger than the AGR turbo I had, and the VNT didnt fit so well, so Im goning to sacrifice a little spool up, but still get the good MPGs on the highway.




 

archemitis

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Joined
Nov 16, 2012
Location
minnesota
TDI
200 Golf, 1974 Westfalia TDI
The oil filter is easy to get to , but I have to remove the intercooler to get the radiator into the service position. Once you fold the radiator down and out you get about 4 inches to get to the IP and the oil filter.

No AC, No Power Steering. Just a good ole alternator and a tensioner.

 

ken.fresno-tdi

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Joined
Jan 3, 2006
Location
Fresno, CA
TDI
95 Eurovan EVC camper with 98 AHU engine (VeganVan02); 01 Jetta ALH engine and parts - waiting for transplant into 97 Eurovan (VeganVan03);05 BEW Beetle
Nice to see someone complete this. How did the electrical/wiring go? Any tricks that need to be figured out? How about mounting the go pedal?
 

archemitis

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Joined
Nov 16, 2012
Location
minnesota
TDI
200 Golf, 1974 Westfalia TDI
right on, do you think an AC compressor will hang too far down ?
It looks like it would sit pretty low and might need some belly pan modification. I would say try it tough! I lifted mine, you just tighten the torsion bar nuts.
 

archemitis

Veteran Member
Joined
Nov 16, 2012
Location
minnesota
TDI
200 Golf, 1974 Westfalia TDI
Nice to see someone complete this. How did the electrical/wiring go? Any tricks that need to be figured out? How about mounting the go pedal?

The wiring was easy, because I just wired it as a stand alone unit. The gauges and dash and most everything is still stock. I need to put in a 4 cylinder cluster to get a working tach.
I used a pedal out of a 2000 golf, so I just welded a steel plate to the old gas pedal mount.
There is something with the old auto tranny. It had a neutral safety switch that wouldnt let the starter spin with the new 5 speed installed. I just traced the starter wire to before this safety switch and got power for the starter solenoid from there.

Im still excited over an oil pan that worked without modification, except for the drain plug has to be moved to the other side. It (the entire system) holds 4 quarts and the level sits just below the rotating part of the crank assembly.
 

ken.fresno-tdi

Veteran Member
Joined
Jan 3, 2006
Location
Fresno, CA
TDI
95 Eurovan EVC camper with 98 AHU engine (VeganVan02); 01 Jetta ALH engine and parts - waiting for transplant into 97 Eurovan (VeganVan03);05 BEW Beetle
Did you replace or modify the in tank fuel pump? Or just let it remain and help give some more pressure to the ALH pump? I'd like to see a pic of the passenger side modified engine mount if you have one. That and the oil pan/pickup mod is what have me waiting to do a ALH conversion.

Re the wiring, if you don't run A/C that makes things a bit easier. Also no cruise control? That requires connecting with brake/clutch switches and stalk switch.

BTW, on my AHU conversion I mounted the intercooler in the front air dam under the bumper. Works great and mounts easily. No problem then pulling the radiator into service position to check oil and work on anything on the front of the engine. If anyone is interested my AHU conversion is documented here: http://kenssite.net/Eurovan/.
 

archemitis

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Joined
Nov 16, 2012
Location
minnesota
TDI
200 Golf, 1974 Westfalia TDI
Did you replace or modify the in tank fuel pump? Or just let it remain and help give some more pressure to the ALH pump? I'd like to see a pic of the passenger side modified engine mount if you have one. That and the oil pan/pickup mod is what have me waiting to do a ALH conversion.

Re the wiring, if you don't run A/C that makes things a bit easier. Also no cruise control? That requires connecting with brake/clutch switches and stalk switch.

BTW, on my AHU conversion I mounted the intercooler in the front air dam under the bumper. Works great and mounts easily. No problem then pulling the radiator into service position to check oil and work on anything on the front of the engine. If anyone is interested my AHU conversion is documented here: http://kenssite.net/Eurovan/.

Im getting the cruise all wired in this week with the pedal switches. I will try to get a good pic of my timing belt side engine mount.
I noticed I did something different.

I used a short Gasser rubber mount in place of the taller diesel rubber puck mount. That made the center hole of the IDI engine mount up to my ALH. It was pretty easy to build once the engine and tranny were bolted together on the floor. I just made the timing belt side the same height and angle as the tranny side mount.

The pickup was just cut in half and rotated then welded back on.

On the fuel pump, I just bypassed the fuel filter with a piece of hose, and cut the hoses going to the feed and return in the fuel pump. No strainer, no lift pump, just two hoses dangling into the bottom of my fuel tank.
 

archemitis

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Nov 16, 2012
Location
minnesota
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200 Golf, 1974 Westfalia TDI
I do have a problem... I only get 10 lbs of boost. I am running a RC stage 3 tune made for a wastegate turbo. I am running the turbo and wastegate off of an IDI 1.9 eurovan motor. It is a Garret gt15.
The same ecu and tune gave me around 17 lbs of boost in another car with a diffferent wastegate turbo.

Could my turbo be bad? could my wastegate be limiting my boost? My MAF sensor checks out good in VCDS and my n75 can be heard clicking on and off.
Rolls coal like crazy.
 

jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
I do have a problem... I only get 10 lbs of boost. I am running a RC stage 3 tune made for a wastegate turbo. I am running the turbo and wastegate off of an IDI 1.9 eurovan motor. It is a Garret gt15.
The same ecu and tune gave me around 17 lbs of boost in another car with a diffferent wastegate turbo.

Could my turbo be bad? could my wastegate be limiting my boost? My MAF sensor checks out good in VCDS and my n75 can be heard clicking on and off.
Rolls coal like crazy.
internal wastegate spring could be rusty or weak or the wastegate may not have enough pre-tension ... never seen this on a tdi but in the past i've seen burned wastegate valve seats on gasser turbos that leak off exhaust pressure... you can test your wastegate opening pressure by applying regulated air pressure incrementally to the WG port until the gate opens
 

archemitis

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Nov 16, 2012
Location
minnesota
TDI
200 Golf, 1974 Westfalia TDI
internal wastegate spring could be rusty or weak or the wastegate may not have enough pre-tension ... never seen this on a tdi but in the past i've seen burned wastegate valve seats on gasser turbos that leak off exhaust pressure... you can test your wastegate opening pressure by applying regulated air pressure incrementally to the WG port until the gate opens
Thanks! I should just start messaging you directly with my questions.

I have applied pressure with a small syringe and it moves shortly after I apply pressure. Ill take it off today and use my compressor and a boost gauge to test it better.
I also made sure it had some preload. Maybe I don't have enough? I did reclock the turbo so I had to reposition the wastegate.
 

archemitis

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Nov 16, 2012
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minnesota
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200 Golf, 1974 Westfalia TDI
Oh, and .622 5th gear with 205/65 15 inch tires is 80MPH at 3k RPMs
The jump from 4th to 5th isnt too bad, but I had the same kind of jump in my old 74 van, so Im used to it. 4th is a very usable gear 35 up to 60 lol.
 

jimbote

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Jul 10, 2006
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spiral arm, milky way (aka central NC)
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Tacoma 4x4 converted to TDI
Oh, and .622 5th gear with 205/65 15 inch tires is 80MPH at 3k RPMs
The jump from 4th to 5th isnt too bad, but I had the same kind of jump in my old 74 van, so Im used to it. 4th is a very usable gear 35 up to 60 lol.
that's awesome! regeared transmissions can be the most expensive aspect of a swap... this definitely keeps your swap inline with the budget build philosophy
 

archemitis

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Nov 16, 2012
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minnesota
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200 Golf, 1974 Westfalia TDI
that's awesome! regeared transmissions can be the most expensive aspect of a swap... this definitely keeps your swap inline with the budget build philosophy
LOL, thats the second time you said budget! Im sure you know that swaps almost never end up being on, or near budget! Like I say every time I do it, "Thats the last motor swap Im ever gonna do".
Looking at some of the other van engine swaps going on right now my swap is most definitely budget. I swear Ive spent my whole summer and 10 grand... good thing I didnt keep track.
 

jimbote

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Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
LOL, thats the second time you said budget! Im sure you know that swaps almost never end up being on, or near budget! Like I say every time I do it, "Thats the last motor swap Im ever gonna do".
Looking at some of the other van engine swaps going on right now my swap is most definitely budget. I swear Ive spent my whole summer and 10 grand... good thing I didnt keep track.
i'm so sorry! was getting your thread mixed up with josh_WA's t4 thread which is titled "budget build" :eek:... either way i like the approach and i can totally appreciate "this is the last swap i'll ever do" refrain ... i contemplating two crazy swaps myself right now :eek:
 

vanbcguy

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Feb 22, 2013
Location
Vancouver, BC
TDI
'93 Passat - AHU mTDI with GTB1756VK
If the wastegate isn't fully closing it'll cause the symptoms you describe... It should have enough preload that you don't see any movement until you're feeding 9-10 PSI to the actuator.

Sent from my LG-H873 using Tapatalk
 

archemitis

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Nov 16, 2012
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minnesota
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200 Golf, 1974 Westfalia TDI
OK, I hate to even admit it... My lines to the N75 were backwards, so it was basically running off of the stock wastegate pressure.
NOW I GOT SOME POWER!
 
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