ALH TDI engine transplant into '84 Vanagon

AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
Zeitgeist, I stumbled onto an article about the RCV causing problems for guys that had installed late model GM engines with AC compressor in older model cars (rat rods, etc.). The article basically said the RCV set-up was not compatible with the older style expansion valve. VWs were mentioned in the article. I have it book marked, but it will take me a while to find it.

Anyway, that article is what prompted me to remove the RCV in the compressor that come on the ALH TDI engine for my project.

Some folks said that the clutch is not big enough to handle kicking on and off. Well, as long as the cycle is long enough to allow the pressure to equalize, it should be fine. However, I am under the impression that the clutch gets 12 volts to kick-in and then the voltage falls off to about 5 volts. Obviously that is controlled by the ECU through fuse 16 in the Jetta, Golf, etc. In the Vanagon set-up, I'm using straight 12 volts ... not sure if that is good for the coil as I have burned out one. But, I think that was caused by a plugged Expansion Valve, as it was plugged and the clutch got so hot that the paint was burned off.
 

Zeitgeist

Veteran Member
Joined
Nov 10, 2004
Location
Cascadia
TDI
'04 Variant and Vanagon mTDI
Thanks for documenting this issue. So just to be clear, underneath the RCV is a hole with SAE threads?
 

AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
Thanks for documenting this issue. So just to be clear, underneath the RCV is a hole with SAE threads?
Nope!

Notice the two pics with RCV in them. Notice the RCV has a nut on it? That nut holds the RCV and the reeds in the center of the assembly. The RCV is not visible from the outside .......... nothing on the outside, other than the model number, to indicate it has an RCV inside.

Also, notice the bolt and nut in the last pic, I used those to replace the RCV as I was eliminating it per the article. I'll try to locate that article tonight and post the link.
 

Zeitgeist

Veteran Member
Joined
Nov 10, 2004
Location
Cascadia
TDI
'04 Variant and Vanagon mTDI
Ach so!

Ok, I'm not sure why I assumed the 7/16" nut was on a stud. It's just a bolt holding the reed retainer star in place. That makes sense. I was puzzled as to why a Japanese compressor had SAE threads.

I'm also beginning to think my expansion valve is faulty, but I'll remove the RCV first.
 

AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
Do a Google Search on > RCV in GM AC compressors

The first thing on the list is a PDF file with the story/article about removing the RCV from the AC compressor when using it in an older system.
 

AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
Thought I'd bring this Thread up for an update.

Last fall (October maybe), the TPS (accelerator) went dead and left me sitting. It was getting dark and beginning to rain. I was able to get it into the parking lot of a school. We were about 40 miles from home. The Brake Switch had also been throwing a DTC.

Anyway, I had it hauled home on a roll-back. Other than a bit of tinkering and some suspension work, I never tried to fix the issue(s) or drive it. So, it has basically sit parked almost a year. I did start the engine numerous times and allowed it to idle to near full operating temp each time.

Well, these are some findings and things I've done.

1. Idling apparently doesn't produce enough boost pressure and neither does the exhaust pressure amount to much. So, the idling resulted in the Turbo dumping a considerable amount of oil out the exhaust at the donut joint. Remember, the engine is laying over on 50 degrees which puts the Turbo drain-hose off spec. Dumping oil by the Turbo has never been an issue even on the long road trips.

2. I've learned that the brake switch malfunctioning causes the TPS to do crazy things and throw DTCs also. Anyway, a new switch solved the problem.

3. The MAP sensor had been malfunctioning resulting in boost spikes up to 25 PSI. So, as part of the maintenance while it's been parked I installed a 3-Bar MAP. The boost is impressive, going up to 21 to 22 PSI. I'm not sure the VNT15 will be able to sustain that much boost.

4. The el cheapo starter I installed about 18 months ago is working great.

5. The AC hose and fittings replacement I did in the summer of 2017 has been okay. There must be a very small leak as I did have to add about 6 ounces of R134a back in mid-summer, 2019 for it to cool properly.

6. I had to replace the junk ball joints and some other front suspension components I installed when I was doing my project. I think I did the suspension work in the summer of 2018.

Well, as I've promised a number of times, I hope to go thru this Thread and finish replacing the Photobucket pics. And, I may do an index or out-line in the first post with links to the various aspects of the build to make it easy to find things.
 

markd89

Veteran Member
Joined
Oct 21, 2009
Location
Los Angeles
TDI
1978 VW Bus 1Z TDI
Good to hear all is well.

FWIW - I've always been concerned about the TPS being a single point of failure. Mine is mounted underneath where it could see some water. I haven't had any misfortunes, fortunately, but I do carry a spare just in case.
 

AndyBees

Top Post Dawg
Joined
May 27, 2003
Location
Southeast Kentucky
TDI
Silver 2003 Jetta TDI, Silver 2000 Jetta TDI (sold), '84 Vanagon with '02 ALH engine
The following are LINKS to the various components involved in doing the ALH engine install in my 84 Tin-top Vanagon. The subject matter is mostly in chronological order. In some links, there will be more than one topic. The narrative is generally there but may be found in the posts that follow. Also, in about all links, it will be necessary to scroll down to find what the reference subject might be. Just use the Post Numbers to find the subject.

I believe this will be very helpful in trying to decipher this huge Thread.

Note: The TDI Club Web Site software was updated in the summer of 2015. I did make an effort over about four years to correct the post page numbers that changed due to the software update. (The Post Numbers are the same.)

Note: All links have been updated. In the topic you wish to dig thru, look at the Post # then click on the link which will take you to the page. Then, scroll to the Post(s) you are looking for.

I hope this helps everyone.
Shoot me a message if you have a specific question rather than posting.


Transmission (this topic is updated with New Links per new website software, 1/2/21)
Post #4, 5 & 8 http://forums.tdiclub.com/showthread.php?t=276798
Shifter Mod for the DK Trans, Post #336, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-12
Comparing a 5-speed with a 4-speed (gearing)
Post #855, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-29
Pulled trans to look for whine
Post #1298, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-44

Flywheel, Clutch, etc., & Related. (this topic is updated with New Links per new website software, 5/17/21)
Post #10, http://forums.tdiclub.com/showthread.php?t=276798
Post #917, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-31
Post #937, 944, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-32
Starter modification for clearance of the G-60 SMF (I later changed to the TDI starter)
Post #953, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-32
TDI Pilot Shaft
Post, #1279, see first photo, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-43
TDI Starter Upgrade
Post #1283, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-43
These are pics of cracked clutch disc
Post #1307, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-44
Below, I ordered the DMF but no documentation of install. I think I installed it May, 2017
Post #1315, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-44

Fuel Tank (this topic is updated with New Links per new website software, 10/13/20, 5/17/21)
I tried to rehab a rusty tank. I am only linking the photos/narrative showing how I modified the fuel level assembly of the Vanagon fuel tank to use the Jetta level sensor.
Beginning with Post #122 & #150, https://forums.tdiclub.com/index.php?threads/alh-tdi-engine-transplant-into-84-vanagon.276798/page-5

Cluster Modification, Jetta cluster and Related (this topic is updated with New Links per new website software, 5/18/21)
Posts #154, 163 and 164, https://forums.tdiclub.com/index.php?threads/alh-tdi-engine-transplant-into-84-vanagon.276798/page-6
Post #166, https://forums.tdiclub.com/index.php?threads/alh-tdi-engine-transplant-into-84-vanagon.276798/page-6
Post #186, https://forums.tdiclub.com/index.php?threads/alh-tdi-engine-transplant-into-84-vanagon.276798/page-7
Post #474 (last two pics), https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-16
Post #616, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-21

Oil Pan and Suction Tube in Pan (this topic is updated with New Links per new website software, 5/18/21)
Post #76, https://forums.tdiclub.com/index.php?threads/alh-tdi-engine-transplant-into-84-vanagon.276798/page-3
Post #159, https://forums.tdiclub.com/index.php?threads/alh-tdi-engine-transplant-into-84-vanagon.276798/page-6
Post #182, https://forums.tdiclub.com/index.php?threads/alh-tdi-engine-transplant-into-84-vanagon.276798/page-7
Post # 286, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-10
Post #345, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-12
Post #378, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-13
Post #551, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-19
The link below is kind of a repeat but has good info
Post #895, 898, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-30
Stainless Steel Oil Pan
Posts #1015, 1016, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-34

Engine Photos and Related (this topic is updated with New Links per new website software, 7/20/21)
Post #62, https://forums.tdiclub.com/index.php?threads/alh-tdi-engine-transplant-into-84-vanagon.276798/page-3
Posts #236 & 237, https://forums.tdiclub.com/index.php?threads/alh-tdi-engine-transplant-into-84-vanagon.276798/page-8
Post # 261 & 265, show making room for the engine in the bay, https://forums.tdiclub.com/index.php?threads/alh-tdi-engine-transplant-into-84-vanagon.276798/page-8
Post #497, random pics of the engine bay, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-17
Post #587, engine start-up narrative, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-20

Mounts, Engine, Transmission & Related (this topic is updated with New Links per new website software, 10/2021)
Posts #241 & 253, https://forums.tdiclub.com/index.php?threads/alh-tdi-engine-transplant-into-84-vanagon.276798/page-9
Posts #258 & 259, https://forums.tdiclub.com/index.php?threads/alh-tdi-engine-transplant-into-84-vanagon.276798/page-9
Post #290, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-10
Post #310, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-11
Post #372, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-13
Posts #383 & 384, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-13
Posts #498, 502, & 503, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-17
Broken engine mount bracket
Post #875, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-30
Post #925, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-31
Post #1198, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-40

Down Pipe, Exhaust & Related (this topic is updated with New Links per new website software, 12/13/22)
Post #259, https://forums.tdiclub.com/index.php?threads/alh-tdi-engine-transplant-into-84-vanagon.276798/page-9
Post #271, 274, 281, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-10
Post #294, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-10
Post #511 & 519, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-18
New Custom Made Stainless Steel Exhaust System
Post #1302, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-44

Coolant pipe return (small black metal pipe mod) and Coolant Flange on the end of the head (links below updated 12/13/22)
Post #266 & 267, https://forums.tdiclub.com/index.php?threads/alh-tdi-engine-transplant-into-84-vanagon.276798/page-9
Post #274, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-10
Post #367, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-13
Below, is a link that shows the Coolant Glow Plugs and mounting hardware (scroll down to see)
Post #378, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-13

Inter Cooler & Related (this topic is updated with New Links per new website software, 11/12/21)
Post #290, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-10
Post #331, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-12
Post #365, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-13
Posts #452, 458, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-16
Post #496, 509 & 510, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-17
Post #604, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-21
Post #1021, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-35

EGR Modification (this topic is updated with New Links per new website software, 12/13/22)
Post #299, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-10
Post #495, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-17
Post #525, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-18

Air Filter Box & Related (Coolant Expansion Tank) (this topic is updated with New Links per new website software, 12/13/22)
Post #317, 318 & 330, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-11

Metal Coolant Pipes (Rehab) (this topic is updated with New Links per new website software, 12/13/22)
Posts #327, 328, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-11

Accelerator Mounting & Related (this topic is updated with New Links per new website software, 7/14/21)
Post #348, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-12

ECU Location & Associated Fuse Panels and Wiring (this topic is updated with New Links per new website software, 12/13/22)
Post #355, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-12
Posts #393, 394, 397, 400, & 402, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-14
Posts #407, 414, 417, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-14
Posts #425, 431, & 432 https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-15
Posts #436, 439, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-15
Posts 461, 465 & 467. https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-16


AC Compressor and Hoses (modification to fit TDI Compressor) (updated with New Links per new website software, 6/16/22 & 12/13/22)
Post #378, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-13
Post #520, (inside the AC compressor), https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-18
In the link below, you’ll see I continued to have issues with AC leaks
Post #1060, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-36

Windshield Washer & Related (this topic is updated with New Links per new website software, 12/13/22)
Post #463, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-16

Vehicle Speed Sensor & Related... (this topic is updated with New Links per new website software, 12/13/22)
Post #469, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-16
Post #694, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-24
Post #1003, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-34
Post #1121, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-38

Clutch and Brake Switches and Related (this topic is updated with New Links per new website software, 12/13/22)
Post #474, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-16

Random Pics, unspecific ... (this topic is updated with New Links per new website software, 12/13/22)
Post #523 & #536, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-18
Post #543, More interior & AC, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-19

Fuel Filter Mount & Related (this topic is updated with New Links per new website software, 12/13/22)
Post #544, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-19

Oil Dip Stick Location & Related (this topic is updated with New Links per new website software, 12/13/22)
Post #551 (scroll down), https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-19

E-Vac Scavenger Crankcase Gas Handling System (blow-by evacuation) (this topic is updated with New Links per new website software, 12/13/22)
Posts #569 & 570, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-19
Post #597, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-20

Engine Cover (this topic is updated with New Links per new website software, 12/13/22)
Post #580, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-20
Post # 564, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-19

Road Trips & Related (this topic is updated with New Links per new website software, 12/13/22)
Trip to Western Kentucky
Post #681, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-23
Trip to Ypsilanti, Michigan, TDI Fest, 2012
Post #707, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-24
Fuel Stats on the Ypsilanti road trip
Post #713, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-24
Summary list of To Do Things after the Ypsilanti road trip
Post #740, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-25
Out with grand kids, etc.
Post #863, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-29
Road trip to Bethel, Maine, 2013 TDI Fest
Post #1141, 1148, 1150, 1152, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-39
Post #1173, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-40
Getting ready for a road trip to Alaska
Post #1241, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-42
Post #1269, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-43

Injection Pump Re-seal and related (this topic is updated with New Links per new website software, 2/11/23)
Re-sealing the IP was done to address a hard-start issue that I had experienced from day one. Long story, short the issue was a bad ground at the transmission mount.
Post #770, 777, 778, 779, & 780, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-26 (link update 1/19/21)
Post #792, related to IP re-seal, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-27
Post #806, IP shut-off valve voltage, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-27

Dash Removal to Replace Fan and Related (this topic is updated with New Links per new website software, 2/11/23)
Post #1022, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-35
Post #1047,https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-35

CV Joints & Related (this topic is updated with New Links per new website software, 2/11/23)
Post #1066, 1069, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-36

Sound Deadening (this topic is updated with New Links per new website software, 2/11/23)
Starts in the link below as narrative only, then pics much later
Post #1130, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-38
Post #1184, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-40

Power Steering Install (this topic is updated with New Links per new website software, 2/11/23)
Post #1183, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-40

Exhaust Gas Temperature sensor and gauge install (this topic is updated with New Links per new website software, 2/11/23)
Post #1250, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-42

Coolant Temp Sensor in Oil Cooler Coolant Return Hose (this topic is updated with New Links per new website software, 2/11/23)
Post #1251, https://forums.tdiclub.com/index.ph...ine-transplant-into-84-vanagon.276798/page-42

Note: I did install a DMF some time prior to the Summer of 2017. However, I did not document with photos and narrative. It works great!
 
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