ALH Samurai

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
You know now that you brought that up,I never thought about filling it.
Kind of too late now:D...will have go slow when fueling up.

The baffle closest to the filler neck has some good gaps so that's not a problem.
I can reach my hand through the sending unit hole with the plasma,I will cut
two 1 1/2" holes in the other baffle.
 
Last edited:

andy2

Veteran Member
Joined
Sep 24, 2004
Location
Bowmanville,Ontario,Canada
TDI
13 Jetta,94 Golf drag car 585bhp,Samurai buggy BHW 300bhp,97 Ram cummins
Nice work with the fuel tank mod! I modded my fuel cell pickup to pull fuel from the rear end of the fuel cell so that there would be no issues.I also keep my fuel cell full to avoid problems.I've yet to starve for fuel when running my buggy on its side or attempting to climb a steep grade.
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Thanx Andy,
yeah I would run out on obstacles like this when really laid over.

I don't plan on doing this with the diesel,more of a really capable camping
rig.
So way back when I was making the full circle adapter plate I made this statement
"How often does anyone take the oil pan off anyway" apparently when the diff makes
a hole in it.I had extreme death wobble because I forgot to swap out the blown steering
stabilizer(since replaced,no more bump steer)

So I cut out the hole and clearanced it.

...and rebuild the tranny,had over 200K on it and the added torque was to much for the worn bearings.
some tranny photos for entertainment only.




Wasn't as hard as I thought removing the tranny,in fact is easier than my `88 Toyota truck.
I was pleased to find no strange wear of any sort,pilot bushing,pressure plate,clutch all looked
good, so brought some piece of mind.
I have coated the fuel tank and it has dried for 3 days,goes back in tomorrow then test drive
again.
 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Under the knife again...
I wanted the selectable locker cause the auto locker was way to squirrely in sloppy snow
conditions.
It was time to fab up the E-locker in the front axle,
Fortunately the locker came with the center housing making this chore easier.

Started by cutting out part of the face where the motor sticks out.
I had already modded the U-bolt and perch with welded in studs cause I knew the motor would be all over it.

Welded in the e-locker housing piece.

Had to trim a fraction of the modded perch
[

Pretty close but makes it.

Ready for some silicone and reassembly.

Added a gusset between the welded studs for a little extra support.

I also re-geared the rear to mach the front (4:10) At 25mph and 31" tires,2nd was over revving and 3rd was lugging,so now I can stay in 2nd.
 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Thanx smelly621
Few more photos on the front locker...
Made a shaft to use with broken motor body so it can be manual.



Then made a lever to actuate it.

I have an old Samurai clutch cable and a 1/4" heim joint that will operate the locker,still have to figure out the handle.
 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
A little update,after 500ish miles it started to get a little clutch chatter and a
slight bearing noise.I knew the alignment was probably out since I never indicated it.
So made a tool out of an old w56 tranny nose piece.

It was off .018 up and down and .008 side to side.
I made some offset dowels and it just wasn't happening,so I took the dowels out
,indicated with all the bolts snugged,got it within 1.5 thou.Tightened all bolts
and rechecked,nothing moved then drilled and pined in place.
Pretty happy now...




I'll get it back together this weekend and test.
Also received my VCDS yesterday so that will be interesting.
 
Last edited:

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
No more clutch shudder and everything is running smooth now.:cool:
Still haven't dug into the wiring yet but got some more fab work done.
Made some shift knobs and got the locker shifters and cables working,they
are effortless to lock and un-lock,so am happy about all that.



Photos of the lockers,still have to make rock guards for them.

And here's a video just for the heck of it...

https://www.youtube.com/watch?v=CEhh4DK6pPk
Thanx for lookin' Guys...
 
Last edited:

smelly621

Veteran Member
Joined
Nov 13, 2008
Location
Sonoma County, CA
TDI
2001 Golf, 2003 Tacoma
Looks super fun, and your manual locker conversion looks very nicely done as well. Jealous of your fabrication skills.

Those trails look fun - can you drop me a pm of where abouts you were? Would like to check them out next time I'm up your way.
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Thanx Smelly621
Not much of an update,I've mainly been taking it out on short camping trips
close to home.I need to tune it up and find someone around here that can do
a timing belt change,but other than that it is like a pack mule on the trails towing
a trailer with four people in it.
Couple of photos with trailer...
Upper Lake Trail

Eddy Trail

Some day I will take on the challenge of re-posting the photos...:(
 
Last edited:

ToddA1

Top Post Dawg
Joined
Aug 3, 2011
Location
NJ 08002
TDI
'96 B4V, '97 B4 (sold), '97 Jetta (scrapped)
I'm confused… How is it you can build it, but you can't do a timing belt?

-Todd
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
I should probably buy the timing tools and familiarize myself with the diesel better,seems
more complicated than a gas engine.I have the vagcom program and have no idea how
to change or delete anything...:)
.
.
Give a man a vagcom program and he will stare at it blankly,
Teach a man to vagcom program and he can tune for a lifetime
 

ToddA1

Top Post Dawg
Joined
Aug 3, 2011
Location
NJ 08002
TDI
'96 B4V, '97 B4 (sold), '97 Jetta (scrapped)
I see, said the blind man... you pulled a running engine and just dropped it in.

-Todd
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Yep
Also I got ahead of myself and didn't mark TDC so now the valve cover has
to be removed and #1 glow plug/injector has to be removed and the front
engine mount to get at the front of the engine......
 

smelly621

Veteran Member
Joined
Nov 13, 2008
Location
Sonoma County, CA
TDI
2001 Golf, 2003 Tacoma
It's not too bad Zook - I don't have a TDC mark on my Flywheel either. The mark on the front timing cover and harmonic balancer will get you close, and then I used a piece of AL filler rod in a GP hole to fine tune the crank position the last time I had the belt off.

For the tools - if I were to do it again I would only buy the tensioner tool, the cam lock, and cam sprocket puller. The cam holder I would make with a few bolts/nuts/ and angle iron. The pump lock pin I would use a drill bit. The crank lock isn't really necessary.
 

ManicMechanic

Veteran Member
Joined
Oct 6, 2017
Location
Saint Cloud, Florida
TDI
03 Golf, 00 Golf, 02 Beetle
You don't need to pull the valve cover or glow plug to do a timing belt. You take off the vacuum pump and bolt the cam lock in it's place. If it fits your on top dead if not your 180 out. The ALH is one of the easier VW motors to do a belt on. I've changed the one in my 03 twice and once each for the other two cars.
 

jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
You don't need to pull the valve cover or glow plug to do a timing belt. You take off the vacuum pump and bolt the cam lock in it's place. If it fits your on top dead if not your 180 out. The ALH is one of the easier VW motors to do a belt on. I've changed the one in my 03 twice and once each for the other two cars.
only if you have the special cam lock tool ttat does not require vc removal... most of us have the standard cam lock
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
Got bored and decided to make a new airbox and cold air intake.
Maybe help drop temps a bit.
It uses a Chevy 6 cylinder filter.


Aluminum box


Inlet piece








Hood Plenum and inlet




The hood scoop is 6.5 sq. in.
The filter box is 8.5 sq. in.
and the turbo inlet tube is 4.9 sq. in.
hope that works out?
 
Last edited:

Millennium Falcon

Veteran Member
Joined
Nov 2, 2016
Location
Central pa
TDI
2003 jetta wagon, 1949 willys cj3 ALH TDI swap
I just did my timing belt without the tdi flywheel.... I went smoothly. I let you know for sure once i fire it up. I turned it over by hand about 10 times and every time all the locking tools slid right in and the cam lobes were in the right spot. I did use the filler rod in the glow plug hole just as a double double check. It wasnt bad at all. I marked TDC on the back of my jeep flywheel inside the started opening.
 

jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
I should probably buy the timing tools and familiarize myself with the diesel better,seems
more complicated than a gas engine.I have the vagcom program and have no idea how
to change or delete anything...:)
.
.
Give a man a vagcom program and he will stare at it blankly,
Teach a man to vagcom program and he can tune for a lifetime
Like your signature on this quote, nice air box too. How did you seal it to the hood. Several cars did that in the late 60’s and early 70’s. Ram air Firebirds come to mind,
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Downstream of a Volcano
TDI
ALH Samurai
thanx Moto
@ jmodge-ty I went off to the side cause I was afraid of too much water
getting in,this position it is protected from tire spray and rain.
It is tack welded in several spots then sealed with Vulkem sealant.
 
Last edited:

jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
I was thinking air box and filter in the engine compartment to the scoop when the hood is closed. Is there a foam element or something that seals between the filter box and hood?
 
Top