ocelotpotpie
Active member
TDI fuel economy in a Eurovan is something I've wanted to pursue for a while now. I've been driving around a tintop Eurovan and while it's a great van the and I love the VR6, the mileage can be a pain. The trouble-prone 01P automatic in the late model US Eurovan is also poorly suited to the van.
I have a 2002 Eurovan Westfalia that seemed like a great candidate for the swap. So here we go. The plan is to yank the 24v VR6 and the 01P automatic and put in an ALH TDI and a 5 speed manual transmission.
Let me start this by saying that the information and help I’ve found online and through friends offline has been invaluable to getting any of this accomplished. If it were just me and without the internet I’d either never finish this or it would take decades. A special thanks for the help I’ve received from friends including, but not limited to: my friends Russell & Kim, Schwa, and Jason, Eurovan buddies Josh_WA and 04VWGTITURBO.
Here's a terrible photo of what we're starting with:
After lots of combing through information and feeling like I had a decent idea of what I wanted, I started looking for an engine. I got pretty lucky and found a complete ALH engine with engine wiring harness, ECU, and accessories.
The seller sent me a photo before it was removed from the donor car.
The engine was shipped and showed up in a handy crate.
For the transmission I reached out to Quality German in California. They had a DUJ code European TDI 5-speed. This is geared the same as the EWB 02B transmission.
For you gear and math nerds out there, he's what the EWB/DUJ 02B transmission ratios are:
1st gear - 3.778:1
2nd gear - 2.118
3rd gear - 1.304
4th gear - 0.903
5th gear - 0.700 (28:40)
Reverse gear - 3.600
Final drive (R&P) - 4.235
Theoretocal Road Speed @ 3,000rpm 78mph (126km/h)
(Info taken from https://www.vwt4forum.co.uk/showthread.php?t=43861)
I also ordered some of the 4 cylinder TDI swap parts from Quality German for fitment into the T4 / Eurovan chassis.
The transmission was lovingly packaged up and sent off to me here in Washington. I had to go to the UPS depot to pick it up.
Turns out they dropped it off the back of a truck and it "was leaking" so they told me to come get it. When I showed up it had been repackaged. Pretty disappointing but it seemed to suffer only minor damage so we put it in the truck and took it home.
My garage isn't tall enough to fit the van so my friends Russell and Kim graciously offered to loan me the use of theirs. I brought over the engine, transmission, a bunch of miscellaneous parts and tools, and the van all over to the garage. We jacked it up, put it on jack stands, drained the coolant, and then were promptly hit with a ridiculous snowstorm in Seattle.
Stay tuned for more!
I have a 2002 Eurovan Westfalia that seemed like a great candidate for the swap. So here we go. The plan is to yank the 24v VR6 and the 01P automatic and put in an ALH TDI and a 5 speed manual transmission.
Let me start this by saying that the information and help I’ve found online and through friends offline has been invaluable to getting any of this accomplished. If it were just me and without the internet I’d either never finish this or it would take decades. A special thanks for the help I’ve received from friends including, but not limited to: my friends Russell & Kim, Schwa, and Jason, Eurovan buddies Josh_WA and 04VWGTITURBO.
Here's a terrible photo of what we're starting with:
After lots of combing through information and feeling like I had a decent idea of what I wanted, I started looking for an engine. I got pretty lucky and found a complete ALH engine with engine wiring harness, ECU, and accessories.
The seller sent me a photo before it was removed from the donor car.
The engine was shipped and showed up in a handy crate.
For the transmission I reached out to Quality German in California. They had a DUJ code European TDI 5-speed. This is geared the same as the EWB 02B transmission.
For you gear and math nerds out there, he's what the EWB/DUJ 02B transmission ratios are:
1st gear - 3.778:1
2nd gear - 2.118
3rd gear - 1.304
4th gear - 0.903
5th gear - 0.700 (28:40)
Reverse gear - 3.600
Final drive (R&P) - 4.235
Theoretocal Road Speed @ 3,000rpm 78mph (126km/h)
(Info taken from https://www.vwt4forum.co.uk/showthread.php?t=43861)
I also ordered some of the 4 cylinder TDI swap parts from Quality German for fitment into the T4 / Eurovan chassis.
The transmission was lovingly packaged up and sent off to me here in Washington. I had to go to the UPS depot to pick it up.
Turns out they dropped it off the back of a truck and it "was leaking" so they told me to come get it. When I showed up it had been repackaged. Pretty disappointing but it seemed to suffer only minor damage so we put it in the truck and took it home.
My garage isn't tall enough to fit the van so my friends Russell and Kim graciously offered to loan me the use of theirs. I brought over the engine, transmission, a bunch of miscellaneous parts and tools, and the van all over to the garage. We jacked it up, put it on jack stands, drained the coolant, and then were promptly hit with a ridiculous snowstorm in Seattle.
Stay tuned for more!
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