ALH TDI 1.9 L to pickup swap suggestions

[scotsditch]

I have a 2003 vw jetta tdi 1.9L ALH. I'm thinking about taking the motor, (and anything else useful), from the ALH and throwing it into a light pickup. I'd like to get a light 4x4 going with the 1.9L ALH engine. I'm looking for something with a little bit of a bed and the 4x4. I've seen plenty of posts with different pickups. I'm wondering what the easiest light 4x4 is to do a swap like this? Also are there any kits folks recommend to make the job as easy as possible?

 

[JordanTr]

I haven’t done one but I’ve certainly thought about it!
There are lots of ranger and Tacoma threads on here as I’m sure you know.
Some have done 1/2 ton pickups but it’s less common.
Obviously, an uncorked exhaust, upgraded intercooler/turbo, and injectors/tune should be on your shopping list.

A Ford Ranger level 2 would be a nice start for 2 reasons: 1: Torsen rear LSD and 2: no Toyota tax.

Lots of good reading to be had on this site.

 

[cumminsfromthecold]

ALH won't fit easily into a Toyota that's pre 1992, as the vacuum pump will hit the firewall. You'd have to move the axle forward. See e*clipse's swap. The '97 and '98 1Zs and AHUs drop into pre 1992 rigs, although the firewall clearance is very tight.
I've wondered about a TDI in a T100 extra cab short bed, as I happen to really like that size truck. Not sure it's been done, but it probably has.
Enjoy all of the reading as you peruse the list of swaps. You've gotta really want it, and you've gotta read a lot.

 

[PickleRick]

I didn't have any issues fitting the TDI in my 87 Toyota regarding the firewall. You have to go all the way back to 85 to find a solid axle Toyota pickup, they ran IFS after 85. I didn't have to shift anything forward except the frame mount for the steering damper. The transmission did have to move forward a few inches, I was still able to mix and match a few 1st to 3rd gen 4 runner drive shafts to run stock shafts one can find in junk yards. The TDI is taller than the 22r that came in the rig, not longer. The ALH probably has better clearance behind the head than the BHW I used. Running a body lift made for better clearance. If i had used a 4 inch lift that drops the differential and control arms i would not have needed to the body lift and had better drive shaft angles.

I find the older the vehicle is the easier the swap, there's no BCU or other fancy electronics in the cab to have to integrate. Also a little easier on emissions for many locations.

 

[cumminsfromthecold]

I mis-spoke. _Post_ 1992. I chose the ‘84 for plug and play fitment. Thx PickleRick.

I spent $1100 on good motor mount fabrication. I’d recommend investing about the same, but, DO use new oil filled motor mounts. My poly BMW mounts are soft but still no comparison to, say, 300D MBZ oil-filled mounts. My truck vibrates too much at idle; it’s ok above 1200rpms.