archemitis
Veteran Member
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!
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!