AndyBees
Top Post Dawg
- Joined
- May 27, 2003
- Location
- Southeast Kentucky
- TDI
- Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
2002 ALH TDI engine transplant into an '84 Vanagon, non-Westy!
Notice > The link below will take you to Page 45, then scroll down to Post #1328. There you will find links to all the major stuff throughout this Thread. I tried to make it as simple as possible. I may have overlooked something... sorry if I did.
http://forums.tdiclub.com/showthread.php?t=276798&page=89
Note: An asterisk by a red edit (*EDIT) is an indication the info has been reviewed and updated particularly if it references to a Page and Post number.
Everything has been updated as of February 11, 2023
Note to self, all pages have been reviewed/edited and updated as of 2/18/2021, 5/17/21, 10/29/21, 12/14/22 and 2/11/23
Okay guys, followers, dudes, etc., I've finally got to where my project is beginning to move.
First, I want to provide a little background about my thoughts on doing an engine transplant. I had the thought over 25 years ago. In 1984, my wife and I set our sights on doing a trip to Alaska. I commenced looking for a Bay bus to make the trip. However, to me those old VW Vans were so under powered it was pathetic. So, my thought was to do an engine upgrade. I did not have a clue what would work or where to start.
Anyway, while looking and shopping around for a Bay, I stumbled onto an '83 non-Westy 2.0 Vanagon, last of the Air-cooled, with only 49k miles on it (a bit better than the Bay with respect to power)! In April of 1985, I purchased it and in June of '86 we headed north to Alaska on a 28 day trip. At the time, I would never have dreamed I'd go back 6 more times over the next 18 years (1986-2003 the year of the last trip) in the same Vanagon. Wow!
So, from those early days until now, an engine upgrade had been on my mind. However, I did not have the time or know where to start. The idea and thoughts stayed on back burner until 2006. At that time, I was planning for retirement in '08. I began to see that my dream project could possibly begin to happen!
In late summer of '07, I purchased the '84 Wasser Boxer Vanagon. Over the next several months, I did a lot of research and purchased pieces parts here and there. I ran into some road blocks. Some of those road blocks turned out to be beneficial, in that they caused me to look in another direction to accomplish a task. And, of course, there were times I had to put the project on back burner. I have made a few mistakes along the way. I've met a lot of good folks here as well as over at the Samba trying to do similar projects.
So, with this Thread, I, like a few others, would like to document the Conversion as it progresses. I've already posted a few photos, etc., in a few other Threads. I may post some of those same photos again here.
At some point I will acknowledge all those who have contributed to the project one way or another.
I may add posts from time-to-time to explain or bring the project up-to-date.
Engine background: It is from a 2002 Jetta (MrGutWrench's wreck, sorry) with the complete wiring harness, including ignition and valet key, as well as all the other necessary items to bring the Vanagon into the 21st century, if that's possible!
Transmission background: It is out of an '80 (born date: 11/28/79) with the DK code having the 4.57 Ring & Pinion. I rebuilt it myself, adding a .77 4th and a 1.14 3rd. I'm using a bell housing from an '83 Diesel transmission! (engine will lay over on a 50 degree angle).
Note: since 2020, I've been putting together all the necessary pieces parts to build an new DK transmission. It will have the Weddle 413:1 Ring & Pinion as well as upgraded 3rd/4th gear Hub, 121:1 3rd gear and 0.77:1 4th gear. Also, I am working on an oil filtering and cooling system. That is the primary reason it has taken so long to finish the work. The end cost is estimated to be $3500.00 (all labor by me) << these comments were added 12/2/2023.
This photo is of the Diesel bell housing and 1.6 diesel oil pan (two views) <<< back in 2010, I was just learning ... Wow!
This photo is of the Diesel bell housing and 1.9 oil pan unmodified (three views)
Notice > The link below will take you to Page 45, then scroll down to Post #1328. There you will find links to all the major stuff throughout this Thread. I tried to make it as simple as possible. I may have overlooked something... sorry if I did.
http://forums.tdiclub.com/showthread.php?t=276798&page=89
Note: An asterisk by a red edit (*EDIT) is an indication the info has been reviewed and updated particularly if it references to a Page and Post number.
Everything has been updated as of February 11, 2023
Note to self, all pages have been reviewed/edited and updated as of 2/18/2021, 5/17/21, 10/29/21, 12/14/22 and 2/11/23
Okay guys, followers, dudes, etc., I've finally got to where my project is beginning to move.
First, I want to provide a little background about my thoughts on doing an engine transplant. I had the thought over 25 years ago. In 1984, my wife and I set our sights on doing a trip to Alaska. I commenced looking for a Bay bus to make the trip. However, to me those old VW Vans were so under powered it was pathetic. So, my thought was to do an engine upgrade. I did not have a clue what would work or where to start.
Anyway, while looking and shopping around for a Bay, I stumbled onto an '83 non-Westy 2.0 Vanagon, last of the Air-cooled, with only 49k miles on it (a bit better than the Bay with respect to power)! In April of 1985, I purchased it and in June of '86 we headed north to Alaska on a 28 day trip. At the time, I would never have dreamed I'd go back 6 more times over the next 18 years (1986-2003 the year of the last trip) in the same Vanagon. Wow!
So, from those early days until now, an engine upgrade had been on my mind. However, I did not have the time or know where to start. The idea and thoughts stayed on back burner until 2006. At that time, I was planning for retirement in '08. I began to see that my dream project could possibly begin to happen!
In late summer of '07, I purchased the '84 Wasser Boxer Vanagon. Over the next several months, I did a lot of research and purchased pieces parts here and there. I ran into some road blocks. Some of those road blocks turned out to be beneficial, in that they caused me to look in another direction to accomplish a task. And, of course, there were times I had to put the project on back burner. I have made a few mistakes along the way. I've met a lot of good folks here as well as over at the Samba trying to do similar projects.
So, with this Thread, I, like a few others, would like to document the Conversion as it progresses. I've already posted a few photos, etc., in a few other Threads. I may post some of those same photos again here.
At some point I will acknowledge all those who have contributed to the project one way or another.
I may add posts from time-to-time to explain or bring the project up-to-date.
Engine background: It is from a 2002 Jetta (MrGutWrench's wreck, sorry) with the complete wiring harness, including ignition and valet key, as well as all the other necessary items to bring the Vanagon into the 21st century, if that's possible!
Transmission background: It is out of an '80 (born date: 11/28/79) with the DK code having the 4.57 Ring & Pinion. I rebuilt it myself, adding a .77 4th and a 1.14 3rd. I'm using a bell housing from an '83 Diesel transmission! (engine will lay over on a 50 degree angle).
Note: since 2020, I've been putting together all the necessary pieces parts to build an new DK transmission. It will have the Weddle 413:1 Ring & Pinion as well as upgraded 3rd/4th gear Hub, 121:1 3rd gear and 0.77:1 4th gear. Also, I am working on an oil filtering and cooling system. That is the primary reason it has taken so long to finish the work. The end cost is estimated to be $3500.00 (all labor by me) << these comments were added 12/2/2023.
This photo is of the Diesel bell housing and 1.6 diesel oil pan (two views) <<< back in 2010, I was just learning ... Wow!
This photo is of the Diesel bell housing and 1.9 oil pan unmodified (three views)
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