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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 January 28th, 2011, 22:38   #151
AndyBees
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This is a continuation of the Fuel Level Sending Unit & Sensor Mod:

11. This is a view of the ALH potentimeter attached to the modified Vanagon Fuel Level Sending Unit. Notice the small bolts I used to assemble the various parts. As mentioned later, these parts were given a "dab" of Red-Kote to prevent damage from corrision:


12. This is another view of the modified unit.....roughly in the "empty tank" position:


13. This is a view from the other side. In this view, you can see that I added an extension on the modified Vanagon Unit. I also bored a hole near the bottom if the extension. That hole has the plastic pivet point of the potentimeter from the ALH unit in it. Look close and you can see the end of the Float wire. Notice that the ALH Potentimeter is not "exactly" square with the Vanagon unit. It is slightly off square. That angle puts the float higher at the full position and keeps it a little more off the bottom at the empty position:


14. This view shows the Sensor wires in place. They are soldered on the Connector but are Clipped on the Potentimeter. I did not shorten the wires. The extra length was helpful with installation. It was impossible to install the Unit with it bolted together. Thus, working with various tools, I put the float part inside the tank first. Then I carefully bolted the two parts together and added Red-Kote to the bolt heads and nuts. Then, I plugged the sensor wires in place.....they are not crossed. (smile). Also, they were bent in a fashion to avoid contact with the float or float wire:


15. This is another view showing the wires:


16. This is a similar view as above. However, notice, the ALH Potentimeter is "off-set" from the modified Vanagon unit compared to the above photo. The off-set is necessary to allow the float to move thru the full sweep of the potentimeter. It is about 5/16 inch off the bottom at "empty." The first attempts I determined the float was hanging on an edge inside the tank which did not allow the Potentimeter to complete a full swing to the empty position.


17. This is a view of the MODIFIED unit installed in the Vanagon Fuel Tank:


18. Another view of the installed unit:


19. And, here is the final photo of the unit installed in the tank:


Keep in mind, I took far more photos than what's posted here. And, since I only have two hands, I did not take photos of the actual installation process. It was actually installed in two pieces which were bolted (small bolts) and coated with Red-Kote before lowering into place. Although not shown in any of the photos, I did use the large rubber O-ring for sealing the unit head.

Also, there were several trial and error efforts to get it right. The float wire "bends" cannot be given justice with these photos. The tank will probably hold two or more gallons after showing full on the gauge. It will be near empty when the Buzzer goes off!

Due to the very long sweep of the ALH Potentimeter, it was all but impossible to bend the float wire in a manner that accurately reflects both FULL and EMPTY. Actually, I believe due to the Fuel Tank configuration, it would not be possible to bend the float wire in a fashion to show Full without empty being reflected with almost a half tank of fuel. It was a give and take task! Hopefully, it will serve the purpose square in the middle of the Ball Park.......smile!

The Fuel Tank is not ready for the final coat of paint (Truck Bed liner).

Okay, hope this is informative to all who reads!
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2000 Jetta TDI, 50+ overall average (no tune)
300k mile mark on 12/28/11
456 fill-ups, in Excel spreadsheet, 345k miles...
'84 Vanagon ALH TDI engine (32 mpg) Malone Stage 1 tune, Polaris Diesel ATV, Allegro Bay RV 5.9 cummins, VWs 41 years, VW diesels 34 years, ALH TDIs 12 years

Last edited by AndyBees; January 10th, 2013 at 18:54. Reason: Clarification, Remove PhotoBucket photos and replace with TDI gallery pics
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Old February 5th, 2011, 04:45   #152
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Update: I don't have the oil pan ready, yet!

I've been re-calculating the space in the Vanagon Cluster housing for customizing to accept the ALH Cluster. The space is there for a good fit. This is going to be a challenge.

As a "borrowed" photo in a previous post refects one example of installing the ALH Cluster, I'll be attempting another method. The fact that the brake master cylinder is located directly behind the cluster, space is limited. My intent is to position the ALH cluster at the extreme back of the Vanagon Cluster housing. That will allow room for the Lexon (plexiglass) cover to fit and appear to be recessed. The other Vanagon switches, etc., on either side of the housing will still be in use.

Hint: The TDI ALH cluster fits exceptionally well on the width measurements, but the front to back thickness is the real challenge (remember the brake master cylinder). Also, the up and down demension is very close.

Photos will document the procedures!
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2000 Jetta TDI, 50+ overall average (no tune)
300k mile mark on 12/28/11
456 fill-ups, in Excel spreadsheet, 345k miles...
'84 Vanagon ALH TDI engine (32 mpg) Malone Stage 1 tune, Polaris Diesel ATV, Allegro Bay RV 5.9 cummins, VWs 41 years, VW diesels 34 years, ALH TDIs 12 years

Last edited by AndyBees; February 5th, 2011 at 04:51. Reason: Ad info
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Old February 5th, 2011, 10:06   #153
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nice work Andy!... I sometimes wonder on all these conversions what people will think in the future...maybe even us...one day when I'm older I may happen upon someones conversion tucked away in a back yard with electric cars whizzing past...and say to myself "i remember seein' this one on TDI club"
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Old February 17th, 2011, 20:04   #154
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Another update: Here are some photos of the Vanagon Cluster Housing and the TDI Cluster.

I've done a lot of measuring and it appears the TDI Cluster will fit inside of the Vanagon Cluster Housing....and recessed! Hopefully these photos will illustrate what I will be attempting to do. (explanations are at the top of the photos)

This photo is an aerial view of a Vanagon Cluster Housing. Notice the two lines from left to right. I will cut the housing along those lines to create an opening approximately 2 inches wide (1 7/8). The TDI cluster (after modification) will fit down in the hole. Of course the center section of the Vanagon Cluster will be cut out. Those lines represent my first consideration as to the positioning of the TDI Cluster. However, after making additional observations of the position of the Brake Master Cylinder, I believe the TDI cluster can be moved back about 5/16 inch or 3/8 inch more, thus giving it a more recessed appearance. (The Vanagon brake master cylinder fits between the two sides of the cluster.)



Another view from the side.........notice where the cuts will be made.


An aerial with the TDI Cluster sitting in front of the Vanagon Cluster Housing


A side view with the TDI Cluster sitting in front of the Vanagon Cluster Housing


This view shows the TDI Cluster in front of the Vanagon Cluster Housing (right side)


This view shows the TDI Cluster in front fo the Vanagon Cluster Housing (left side)


The perspective makes the TDI cluster look larger. However, once the top, bottom and sides are "trimmed" it will fit quite well.

As I progress, I'll edit this Post to include additional photos!
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2000 Jetta TDI, 50+ overall average (no tune)
300k mile mark on 12/28/11
456 fill-ups, in Excel spreadsheet, 345k miles...
'84 Vanagon ALH TDI engine (32 mpg) Malone Stage 1 tune, Polaris Diesel ATV, Allegro Bay RV 5.9 cummins, VWs 41 years, VW diesels 34 years, ALH TDIs 12 years

Last edited by AndyBees; February 18th, 2011 at 06:27. Reason: Add info
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Old February 19th, 2011, 04:47   #155
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sweet.....I love this stage of a conversion....who hosts your pictures?..they are nice and big!
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Old February 19th, 2011, 06:58   #156
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I have a Kodak EasyShare DX7630 ($299.00 at Walmart). Although down thru the years we've always taken photos on vacations and such, about 6 years ago, my wife got interested in wildlife and flower photos. I purchased the camera for her.

Well, last year she went big-time (about $2500.00) with two new cameras, lense, etc. So, I ended up with the EasyShare.

Story doesn't end there. We always get out on weekends (in the Vanagon) and do photography. Well, the EasyShare went missing.........for three months, I looked high and low for the camera.....retracing my activities to the point the wife and I had words over my obsession with trying to find the camera.................Then it hit me, go on ebay and see if I can find one.

Low and behold, I found a very nice EasyShare for $57.00 shipped....the works, everything! Well, would you believe the other camera that had gone missing showed up..........in her sewing stuff...LOL.

I use HP PhotoSmart program and PhotoBucket online!......I'm still learning! She uses picnic on-line and enters contests, posts on FB, doing wildflower cards, etc., getting a tax number soon..........dang!
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2000 Jetta TDI, 50+ overall average (no tune)
300k mile mark on 12/28/11
456 fill-ups, in Excel spreadsheet, 345k miles...
'84 Vanagon ALH TDI engine (32 mpg) Malone Stage 1 tune, Polaris Diesel ATV, Allegro Bay RV 5.9 cummins, VWs 41 years, VW diesels 34 years, ALH TDIs 12 years
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Old February 24th, 2011, 14:21   #157
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Sewing stuff, that's priceless . The cluster looks good, I have been thinking about maybe putting a beetle cluster into my Westy. If I do that I'll document it and probably do some type of custom cover/dash assembly (I have a new nb cluster).

We're in the middle of looking/buying a house, so I am not on here as much recently. When life settles down I'll post some more on my thread and update some things.

Jon
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Old February 24th, 2011, 19:35   #158
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Hey, my wife is: an excellent cook, loves to sew, likes to garden, cans food, freezes food, etc................ and, loves to travel in the Vanagon!

Yes, Jon, don't forget us..........keep us posted!
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2000 Jetta TDI, 50+ overall average (no tune)
300k mile mark on 12/28/11
456 fill-ups, in Excel spreadsheet, 345k miles...
'84 Vanagon ALH TDI engine (32 mpg) Malone Stage 1 tune, Polaris Diesel ATV, Allegro Bay RV 5.9 cummins, VWs 41 years, VW diesels 34 years, ALH TDIs 12 years
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Old February 28th, 2011, 14:17   #159
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Here is a photo of the Vanagon 1.6 Diesel Oil pan overlayed on the ALH engine oil pan. This info is at the request of rsxsr!

The X indicates ALH and Vanagan oil pan bolt holes that align. The other holes are either obviously for the ALH or the Vanagon oil pan.

The ALH pan is in dark double (inside and outside) markings. I apologize for the shakey hand, but it was very difficult to work thru the ALH oil plug drain hole with a magic marker to get the inside marked. The Vanagon oil pan is the light pencil marking! The oil pan drain plug hole on the Vanagon pan was too low to work from (now, if you believe all that, you'll believe anything I tell you....LOL)

The bottom of the photo is the right side of the engine (you are looking up from the bottom rather down from the top)....... notice the outward arc of the Vanagon oil pan. That's to accommodate the oil pump and "pump drive shaft" for the vacuum pump on the 1.6 engine! The oil pump drive shaft is powered by the intermediate shaft! The ALH engine does not have an intermediate shaft....the vacuum pump is on the end of the head and powered by the Cam. The oil pump for the ALH is powered by a sprocket running off the Crankshaft on the harmonic balancer end of the engine!........also, notice the ALH engine is a little longer!

Hope this works!



Here are some photos of the ALH oil pan bolted to the engine with the Diesel Bell housing on too! All coments are at the top of photos!

This photo just shows the ALH pan, engine block and diesel bell housing mated.



This is a view of the same area as the above photo, just a little farther down. Notice the bell housing bolt hole almost in alignment with the ALH pan oil.


Another view, zoomed out and different angle


Another view



Here is a bottom view.........looking up! Notice how the vent holes are almost 100% aligned. And, the access to the back oil pan bolts line-up perfectly thru the holes


This is a side view looking toward the bottom and back of engine.......notice I did not install the dust cover before putting on the diesel bell housing. You can see the bolt holes for the diesel bell housing and ALH oil pan ....not even close! Of course the bottom of the ALH oil pan will be cut off and modified to fit!


Here is a photo of the Diesel Oil Pan at front of the ALH engine near the corner where the AC pump is located....does not match well at all! It also makes contact with the oil pump sprocket/chain.


This is a photo of the Diesel oil pan next to the Diesel Bell housing. The end actually touches the crankshaft. You can see the two center bolt holes in the ALH block. Those holes actually align with the Diesel oil pan when it is slide to the rear. See diagram at the beginning of this post


I believe it would be easier to modify the front part of the Diesel Oil Pan to fit the ALH engine than try to mod the rear! My plans are to mod the ALH oil pan!
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2000 Jetta TDI, 50+ overall average (no tune)
300k mile mark on 12/28/11
456 fill-ups, in Excel spreadsheet, 345k miles...
'84 Vanagon ALH TDI engine (32 mpg) Malone Stage 1 tune, Polaris Diesel ATV, Allegro Bay RV 5.9 cummins, VWs 41 years, VW diesels 34 years, ALH TDIs 12 years

Last edited by AndyBees; March 2nd, 2011 at 07:22. Reason: Clarification & add photos
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Old February 28th, 2011, 21:02   #160
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yup....looks like the extra pan length is for oil pump chain and sprocket clearance...I had no Idea the 1.6 and the TDI were so close together in the pan configuration, down to nearly all the bolt holes!!...are you thinking of modifying the 1.6 pan rail for the ALH?
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Old February 28th, 2011, 21:28   #161
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hey Andy...check out the pan angle on this BHW !!!...not quite 50 degrees but alot closer than the ALH ... http://www.myturbodiesel.com/images/b5/engn/pull11.jpg
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Last edited by jimbote; March 1st, 2011 at 03:53.
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Old March 1st, 2011, 08:21   #162
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Yes, Jimmy, that looks like an oil pan that would work with minor mods!
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2000 Jetta TDI, 50+ overall average (no tune)
300k mile mark on 12/28/11
456 fill-ups, in Excel spreadsheet, 345k miles...
'84 Vanagon ALH TDI engine (32 mpg) Malone Stage 1 tune, Polaris Diesel ATV, Allegro Bay RV 5.9 cummins, VWs 41 years, VW diesels 34 years, ALH TDIs 12 years
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Old March 4th, 2011, 22:27   #163
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This update is sort of a continuation of Post #154 CLUSTER Modification

The following photos are of the Vangon Cluster Housing being "cut" to accept the TDI Cluster. Also, the mods and fabrication of the TDI cluster are included. I took far more photos that displayed here.

Note: Any comments will be at the top of each photo!

1. This photo is a bottom and back view of the Vanagon Cluster. It was easier to "mark" the cut line(s) with masking tape.


2. Another view of the bottom of the Vanagon cluster depicting cutting operation........Dremel!


3. Top view from back


4. Bottom side view depicting cut


5. This view shows the notch that is used to slide the TDI cluster in place....see later commets and mod to the TDI Cluster for the notches


6. Front view of Vanagon Cluster ........notice cut just above bottom edge, center


7. Center section of Vanagon Cluster......is out


8. Vanagon Cluster after center section is out


9. Another view of the Vanagon Cluster after center is cut out


10. TDI cluster, bottom view showing the tabs and protruding lip.........all gets cut off!
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2000 Jetta TDI, 50+ overall average (no tune)
300k mile mark on 12/28/11
456 fill-ups, in Excel spreadsheet, 345k miles...
'84 Vanagon ALH TDI engine (32 mpg) Malone Stage 1 tune, Polaris Diesel ATV, Allegro Bay RV 5.9 cummins, VWs 41 years, VW diesels 34 years, ALH TDIs 12 years

Last edited by AndyBees; March 4th, 2011 at 22:52. Reason: Correction
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Old March 4th, 2011, 22:29   #164
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Cluster Modding continued:

11. TDI cluster "taped up" to keep dust and cuttings out while being cut/trimmed


12. TDI cluster with support installed on end (still taped up)


13. Another view of the support


14 Another view of the support ......... two layers of card board sandwiched with JB Weld


15. TDI Cluster, front view with the supports on each end (they slide down thru the slots on each side of the Vanagon modified cluster


16. Trim for the TDI Cluster to cover any "screw-ups" with the Drimel


17. TDI cluster with trim in place. I later did more trimming and polishing. It is now glued and drying! Compressed air blew away all dust.


18. TDI cluster just sitting inside the Vanagon modified cluster housing (trim not installed)


19. And, lastly, a Draft of the Lexan only laying in the Vanagon Cluster Housing
I plan to cut a new piece........... this on just doesn't fit to suit me!


As you can see, the TDI Cluster will have depth because it will sit back about an inch from the Lexon. I plan to use black flelt to "tighten" up the fit when the TDI Cluster is placed inside the Vanagon Cluster housing...........and, of course, it will all be nice and clean!

The re-set pegs (clock and trip-ometer) on the TDI cluster will rest on the top of the bottom edge of the Vanagon Cluster Housing. The holes in the Lexan for them will be right on the edge.....just another darn challenge!

Damn, this has been more challenging than doing the Fuel Tank and Fuel Level Sensor!
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2000 Jetta TDI, 50+ overall average (no tune)
300k mile mark on 12/28/11
456 fill-ups, in Excel spreadsheet, 345k miles...
'84 Vanagon ALH TDI engine (32 mpg) Malone Stage 1 tune, Polaris Diesel ATV, Allegro Bay RV 5.9 cummins, VWs 41 years, VW diesels 34 years, ALH TDIs 12 years

Last edited by AndyBees; March 4th, 2011 at 22:58. Reason: Change photo, and comments
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Old March 5th, 2011, 05:01   #165
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awesome work man!! ....you're driver interface is lookin' good
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