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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old April 5th, 2020, 13:31   #1
aksportsman
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Join Date: Apr 2020
Location: Washinton
Default ALH Samurai

Hello all!! I recently acquired a 1987 Sami with 80,000 original miles. Super clean, for $500. Then I found a 2002 Jetta TDI fully loaded with 130,000 on it for $1200. The transmission is even good so ill probably make money by parting it out. The best part was he included a spare low mile 11mm injection pump for free ;D. So these two now need to be married :-* and I need some guidance. Ive found several good threads on the same build, but have a few questions... I want to just do the bare minimum for lift as I just want a good solid daily driver, not a wheeler, so 3" suspension and just decent a/t tires. What gearing should I use with this swap? Also was considering using a Toyota tranny over the Sami one. Just got to look at lengths and such. Can anyone speak of a good tranny suggestion for this application? Also I found a good forum for the wiring harness to get rid of the unnecessary stuff, but any suggestions would be great! Also I keep seeing conflicting forums on whether the various conversion companies make motor mounts for this application. Can any one confirm which company sells what? A lot of the posts I found were old, so some things may have changed. For now I am going to try and keep the current injection setup, until I get to frustrated with the wiring harness and go to m-TDI(I actually think it will go alright. Reason being is that this is just a daily driver not a wheeler so I want to keep a lot of the sensors and still keep the ability to chip 8). If anyone has done something like this, or knows of good suggestions on where to take this post, I would GREATLY appreciate it.
Thanks,
Jeff

Last edited by aksportsman; April 5th, 2020 at 13:35.
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Old April 11th, 2020, 06:43   #2
ManicMechanic
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Join Date: Oct 2017
Location: Saint Cloud, Florida
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I'm running a W58 toyota in mine. It has a good overdrive and is about the shortest of the toyota transmissions I looked at. I would stay away from the samurai transmission with an ALH. The samurai clutch is tiny. I would stick with 4.10 gears or higher because with short tire (under 35) you will be holding it at or above 3k to hold 60 mph with any lower a gear. As far as motor mounts I never found any that would work with the ALH in a samurai off the shelf. I made mine myself. Wiring an ALH is easy. If you take a look at my build thread there is a picture of the ECM, relay board, fuse holder that fits under the dash where the stock samurai ECM goes.
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Old April 23rd, 2020, 22:47   #3
aksportsman
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Join Date: Apr 2020
Location: Washinton
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Quote:
Originally Posted by ManicMechanic View Post
I'm running a W58 toyota in mine. It has a good overdrive and is about the shortest of the toyota transmissions I looked at. I would stay away from the samurai transmission with an ALH. The samurai clutch is tiny. I would stick with 4.10 gears or higher because with short tire (under 35) you will be holding it at or above 3k to hold 60 mph with any lower a gear. As far as motor mounts I never found any that would work with the ALH in a samurai off the shelf. I made mine myself. Wiring an ALH is easy. If you take a look at my build thread there is a picture of the ECM, relay board, fuse holder that fits under the dash where the stock samurai ECM goes.
.


Man that is quite a build! You did EXACTLY what I want to do. I sent you a message if you could respond
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