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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 February 25th, 2017, 09:57   #1
archemitis
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Default ALH in to a Eurovan T4

About 8 months ago I purchased a 1993 Westfalia Eurovan with 278k miles on it. It still runs and drives great, but I dont feel safe driving it across the state, let alone the country, so I decided to do a Diesel swap before I even bought it. Its been a few month of collecting parts, and a whole lot of reading and asking questions, but I have finally started making real progress. The ALH was never bolted into a T4 (as far as I can tell) so there is no VW example to copy.

First off the ALH bolted to the Eurovan 5 speed transmission. It does fit!



The original oil pan prevented them from bolting together because of the lower bell housing mounts. I also tried a hybrid oil pan. After my hundred dollar experiment I realized I had clearance issues at the CV extension on the transmission. I ordered an all steel pan and it bolted right on. There is still very minimal clearance for the CV



The Original IDI engine that this transmission came bolted to has a steel oil pan with no lower bell housing mounts. The tranny bolts to the engine with just 4 bolts. the top two and the two on the dowel pins. At first I was unsure about using a steel pan because of the rigidity of the engine to tranny mount, but VW did it from the factory with only 25 or so less horse power, so I should be cool.



The metal plate from the IDI Eurovan engine fills this gap.



This piece has to be modified. The rear main seal is a little different between the ALH and the AAZ so I will grind out the center where the bolts go into the block, leaving it sandwiched between the tranny and block with the 4 large bell housing bolts holding it.



The oil pan and oil pickup is the crux of this project, but I think the steel one is the key. You can see the Eurovan angle is completely different from the golf.



So the oil drain plug is at the high point of the pan. I have a steel weld in drain plug kit on its way to put it in the correct location. I think the oil pickup will be fine, and the dipstick may have to be remarked.

The turbos I have to work with are both wastegate turbos. One is a KKK, from an AGR that I have ran on this engine before.





And the other turbo is from the AAZ style engine that came in the Eurovan.



Im pretty sure Im going to run the turbo that is already bolted to the ALH unless I run into clearance issues when I go to installing the lump.

Other than that I really only have to make a motor mount for the passenger side and I have a plan for that using the stock ALH engine mount.
The 5th speed cover unbolts just like a golf so I am going to put a 5th gear more suited to the ALH sweet spot. I have already ruled out a 6 speed, or a 6 speed conversion.



The stock ALH golf clutch and G60 flywheel fit. SO I ordered a south bend stage 2 for a MK4 golf with an AHL.


Other than that I have 1019 nozzles, Stage 3 Rocketchip Tune, a big front mount, and a 3 inch exhaust.


Im happy it has bolted all together like the internet said it would. Its always scary to spend a big chunk of money without knowing for sure it all fits. I hope I havent forgotten anything and I would appreciate any feedback yall have. I appreciate all the help many of you have offered me to get me this far.
Its just got cold again up here in Minnesota, so HOPEFULLY I will get to installing it very soon, with more pictures and questions to come!
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Old February 26th, 2017, 09:18   #2
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Just bought a Eurovan yesterday for a swap. Trying to decide which motor to use....1Z...ALH...Yea, oil pan is an issue with the ALH. I do have a couple of the steel pans.
Was trolling youtube last night and saw a Eurovan with a PD motor in it. Might that be a factory aluminum pan that will work with our application?
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Old February 27th, 2017, 07:05   #3
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Yes, there are (in theory) some oil pans that VW made that are supposed to fit... The T5 with a 4 cylinder TDI. Theres a guy that is rumored to have a kit. I decided to use what was available in the US. Theres a guy in Portugal that installed an ALH actually an AGR, same thing only different turbo.
HE said "The pickup tube and the sump are from the AXB. It's not prefect since I can't use the oil plug to change the oil, because of the angle, but it's bigger and can take more oil. I also had to cut a bit of the sump near the gearbox Bellhousing."

1z and AHU would bolt right in. The ALH fits, just a little more work. No big deal compared to other vehicles.
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Old February 27th, 2017, 09:53   #4
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Nice to see your conversion is happening with the ALH. I'm eager to see how your intercooler setup goes. I'm still floating my AHU intercooler above the engine. Also interested to see what you do in regards to the dipstick. Nice work.
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Old September 18th, 2017, 12:12   #5
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Hallo i am frome germany. i got an ASV TDI Polo Variant. Try also to put it into my eurovan (T4) 1.9 TD ABL . Can you tell me how you have fix with the cable issue `?
and i got also the gear box 02J with cable , i tried to put it also into the eurovan ,but i think it is not going to be easy.
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Old September 18th, 2017, 19:19   #6
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i would definitely rethink the oil pickup tube, it's slightly angled rearward to accomodate the 15 degree rear lean of an alh... you're now rolling the engine forward around 30 degrees so the pickup will now be pointing away from the oil supply ... Frans is now making a kit for T4 alh conversions and he supplies a new pickup to go along with the modified ALH pan
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Old October 9th, 2017, 07:57   #7
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Its in and driving.
Oil pan ended up being a generic stamped steel pan. It doesnt have the bell housing bolts, and extra ribs and casting that got in the way with the aluminum pan.
I cut and welded the oil pickup tube to point towards the ground instead of the rear of the vehicle.
Lengthened my original dipstick tube from the golf, welded on about 8 more inches to the stick and remarked it... lengthened the tube to ease checking it.
Used the original eurovan 4 cylinder engine mount, just had to weld on two tabs, and drill two holes...

Really alot of easy things to accomplish without expensive parts from some importer guy that doesnt tell you what hes sending you off of what car.
Im a big fan of making things work myself.

As far as my experience just told me, anybody could put an ALH into the Eurovan. Not as scary as some people make it seem... Just jump in there and start trying stuff.

Pics to come....
Just dont buy mystery parts from some guy that tells you its the only way to do it. =]
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Old October 9th, 2017, 15:36   #8
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Cool. I wondering also if you are able to still fit the belly pan. I had to modify mine for the AHU I put in because of how low the power steering pump sits. With that, did the power steering high pressure side reach or did you need to extend it? What did you go with on the 5th gear ratio?
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Old October 9th, 2017, 20:26   #9
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did you take a pic of the modified 5 cylinder engine mount ? also how is the clearance for the filter housing and IP to the fans ? are you running ac ?
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Old October 11th, 2017, 12:11   #10
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Quote:
Cool. I wondering also if you are able to still fit the belly pan. I had to modify mine for the AHU I put in because of how low the power steering pump sits. With that, did the power steering high pressure side reach or did you need to extend it?
Instead of keeping the PS pump and the pulley that is so low I removed mine and had a new PS pump high pressure line made to fit a mini cooper PSP and mounted it as a stand alone EHPS pump. Should be interesting to see how it works.

I haven't messed with 5th gear yet. We'll see which one I want to go for, I'm thinking at least .681, but likely .652 and theres a .62 or lower floating around somewhere with Darkside Development.
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Old October 12th, 2017, 10:07   #11
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<a href="http://s67.photobucket.com/user/archemitis/media/Eurovan%20TDI/IMG_20170225_090943889_zps6v9pocti.jpg.html" target="_blank"><img src="http://i67.photobucket.9pocti.jpg"/></a>

Heres where I started, It was a 4 cylinder mount from the IDI that came in the Eurovan. I used the original center hole, which matched the IDI and the ALH. I ended up adding an ear to the top to match another previous existing hole on the ALH. It worked pretty well. Ill see if i got a got pic of it completed. I got kinda hasty with taking photos, and forgot a few things.

I dont have AC or PS! Im just going to use the excuse that I am looking for the ultimate MPG.

The injection pump and oil filter are close to the stock fans on the short nose van, but they do not touch, even when the engine is rocking around.

I went .622 on the 5th gear.

Last edited by archemitis; October 12th, 2017 at 11:01.
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Old October 12th, 2017, 11:00   #12
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Also... big FMIC! Also, I gotta find the pic of the 3 inch exhaust, Including downpipe! It barely fit.



I also used the stock eurovan turbo, as it was a little bigger than the AGR turbo I had, and the VNT didnt fit so well, so Im goning to sacrifice a little spool up, but still get the good MPGs on the highway.




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Old October 12th, 2017, 11:31   #13
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looking really good, i like your budget based approach... how's it looking for getting to the oil filter? and maybe i missed it but are you running an AC compressor ?
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Old October 12th, 2017, 11:38   #14
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The oil filter is easy to get to , but I have to remove the intercooler to get the radiator into the service position. Once you fold the radiator down and out you get about 4 inches to get to the IP and the oil filter.

No AC, No Power Steering. Just a good ole alternator and a tensioner.

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Old October 12th, 2017, 14:11   #15
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right on, do you think an AC compressor will hang too far down ?
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