Economy - Longevity - Performance
The #1 Source of TDI Information on the Web!
Forums Articles Links Meets
Orders TDI Club Cards TDIFest 2016 Gone, but not forgotten VAG-Com List Unit Conversions TDIClub Chat Thank You

Order your TDIClub merchandise and help support TDIClub

Go Back   TDIClub Forums > VW TDI Discussion Areas > TDI Conversions

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.

Thread Tools
Old August 1st, 2020, 18:42   #1
Veteran Member
Join Date: Apr 2016
Location: Virginia
Default //// ALH TDI into 2005 Dodge Gran Caravan ////

Hi All,

My Caravan's 3.8 V-6 is starting to burn a little oil so I figure it may be time to start looking for a solution .... It's not burning or leaking alot and the rest of the van is in great mechanical shape despite 336K mostly highway miles (well mostly highway since I got it about 150K ago).

I know other caravans have been done but I think they were earlier models and or they used the 5 speed from the Jetta.

My preference is to actually use the existing automatic in the Caravan because :

1) automatics are easier for other people to drive ... not everybody can drive a stick and I don't want them learning on my vehicle!

2) The gearing of the trans seems to be well suited for the TDI engine .... I will know more for sure after I install my Scan Guage II but looking at the tach and GPS speedo, it looks like the gearing is such that the TDI is spinning fewer RPM's at speed .... Almost like changing out the 5th gear on our 5 speeds for lower engine RPMs at speed (I'll try to see what engine speeds are in other gears but I have not done that yet).

3) I'm thinking making an adapter plate for the engine / tranny and output shaft converter is easier than trying to graft in the TDI / 5 Speed and worrying about welding up the CV Axles ...

Also since the van is heavier than the Jettas, the weak link would not be the smaller (presumably weaker) jetta tranny / shafts.

5) I'm thinking the Caravan tranny may be computer controlled (have not researched yet), but I'm thinking all I have to do is figure out what sensors are on the engine of the dodge and rig them up onto the TDI engine (hopefully there is a mechanical / optical sensor of sorts to read engine RPM etc).

6) The V6 engine has a manual throttle cable so it would be easy to use the TDI throttle to control the TDI engine.

7) I'll use the engine accessories off the minivan (AC compressor , Alternator, PS Pump etc ) since they are already sized to handle the larger volume of the interior (well at least from the AC standpoint).

8) I'm thinking custom pipes to keep the stock caravan radiator.

9) I'm assuming I need to find weaker front springs since the TDI may weigh less than the 3.8 V6 but I'll have to research that ( on the flip side people often install VR6 springs into jettas so maybe keeping the factory stock springs will be OK?

10) custom motor mounts would be needed

11) I'm thinking I need to keep the guage cluster from the TDI and use that instead of the caravan's guages?

12) I think a return fuel line would nave to be plumbed in to the fuel tank ... BUT the electric fuel pump should be a plus feature to ensure fuel to the injection pump (no more air bubbles in the fuel line!) and easy to prime in case fuel runs out

What do you think? Anything else to think about?

I'm wondering how the preformance / MPG s would be ?

Any input would be appreciated.


2003 Jetta tdi wagon , 5 sp, 316k miles, 11 mm pump, DLC 520, Malone stage 1, P205 70 R 15 Ecopias on Avus rims, hammer mod
Andyinchville1 is offline   Reply With Quote
Old August 1st, 2020, 21:00   #2
Veteran Member
Mozambiquer's Avatar
Join Date: Mar 2015
Location: Versailles Missouri

I think that sounds like a good swap.
We used to have a first gen caravan with a Mazda RF Diesel engine from a Ford escort. It was turboed, but not tons of power and it did pretty good so I think an alh would do a lot better.
Hope you have fun!

Sent from my S60 using Tapatalk
Mozambiquer is offline   Reply With Quote

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
Preface: ALH TDI Conversion in 2005-2010 Dodge Charger Strivous TDI Conversions 3 June 5th, 2017 11:43
1995 Dodge Caravan TDI...maybe, it's time to move on ranchero76 TDI Cars for Sale/Wanted 13 September 7th, 2016 22:00
95 Dodge Caravan TDI ranchero76 TDI Conversions 38 July 21st, 2013 23:23
07 Dodge Gran Caravan Claudio General Automotive 14 July 8th, 2011 05:53
TDI in 2000 Dodge Caravan?? gizmocska TDI Conversions 0 March 16th, 2007 23:13

All times are GMT -7. The time now is 20:10.

Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2020, Jelsoft Enterprises Ltd.
Copyright - TDIClub Online LTD - 2017
Contact Us | Privacy Statement | Forum Rules | Disclaimer
TDIClub Online Ltd (TDIClub.com) is not affiliated with the VWoA or VWAG and is supported by contributions from viewers like you.
1996 - 2020, All Rights Reserved
Page generated in 0.14076 seconds with 13 queries
[Output: 55.98 Kb. compressed to 51.86 Kb. by saving 4.12 Kb. (7.36%)]