TDI Conversion project success stories (short please)

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
I've been thinking about starting this Thread for some time. It would be interesting to read some short stories about your project to include:

1. Engine and Vehicle installed
2. Date placed in service
3. Miles/Kilometres rolled-up thus far
4. Minor issues
5. Major issues
6. Link to your project
7. Any other brief comments of interest (a couple of photos would be nice)

..........................................................................................
Okay, this month my ALH TDI install in the '84 Vanagon is 3 years old.

1. ALH in '84 Vanagon (non-Westy)
2. August 2012
3. Over 46k miles, (129k to 176k)
4. Minor issues - lots of electrical issues related to how I spliced the wiring. However, it has never left me sitting beside the road.
5. Major issues - nothing (Edit: Coming up with an oil pan was a big challenge, for me and my welders)
6. This link is roughly at the point I got the engine started: http://forums.tdiclub.com/showthread.php?t=276798&page=40
7. We did take it on an almost 11k mile road trip to Alaska for 33 days in July-August 2014
Link to road trip: http://forums.tdiclub.com/showthread.php?t=417129

Below, engine pic about half way through the road trip to Alaska, July 2014



Below, somewhere in Minnesota on the way to Alaska, July 2014

 
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CFM

Veteran Member
Joined
Dec 13, 2006
Location
Wells, Maine
TDI
1995 Saturn with a 1997 TDI drivetrain.
My Saturn TDI project is still going strong with 107k on the engine swap since I first put it on the road several years ago. Most of the issues I've had with the car were Saturn-related (like the ignition switch cylinder that jammed on me recently), although there were a couple of -15 degree days last winter where it wouldn't quite woof off without a jump start. There was also the time last year when the vacuum pump bolt loosened and I lost oil pressure; being early in the morning with the sun in my eyes, I didn't catch that for a few miles...I'm certain Divine Intervention saved me on that one!

Currently getting mid-sixties on the commute I have now, and I beat a Model A street rod in a stop light Grand Prix with it as well :D
 

vwztips

Veteran Member
Joined
Aug 30, 2009
Location
Greenville, SC
TDI
2005 Passat GLS Wagon TDI 5 spd manual w/BSM delete 2012 Tiguan TDI/DSG 2005 Audi A4 6MQ 2011 BMW X5 35d
Before 2000 Audi A6 2.7t with 6mq EDU. After 2000 Audi A6 with 2.0 BHW TDI and DQS 6MQ. Car needs a paint job and interior work so I picked up a fairly clean 2004 A6 which will be blessed with all the TDI mechanicals this fall/winter. Fun car to drive. The dual exhaust on a TDI are sweet!

Major issues (not really) was modifying the crossover pipe and getting the ECU and Audi components to talk (or not). Minor was pinning out every wire on the BHW harness and the Audi A6. Going to the 2004 A6 Audi decided to change the harness plugs so I will have to do it again and move all the wires to new plugs. Oh joy!
 
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jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
1996 tacoma with 2.0 alh/bhw hybrid
rolled out of the shop march 2011
just north of 67k miles driven since the swap, it's my daily driver
minor issues, not really too many, the truck is a solid driver
major issues:
*four clutches in four years, first one was a bad homemade combo and chattered badly, breaking the disc springs, second clutch was too weak and slipped immediately, third was a TG clutch and only started slipping after a new tune, fourth and final ctx-107/dtx-136 aisin combo is holding well
*discovered adapter plate was not centered properly and was chronically wearing out pilot bushings/bearings, built a jig to center plate and all is happy in the driveline
*fuel pump relay failure left me stranded... shorted out and truck died, replaced the stock high pressure FI pump with a low pressure early ranger FI unit... i suspect the bypass fpr was choking back the stock pump so much it fried the relay ... no issues since
https://forums.tdiclub.com/showthread.php?t=293577
great driving fun truck, cold AC and cruise control, i'm so confident in this truck i'm about to embark in a few days on a trip to southern california and beyond :)
 
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oil_me

Veteran Member
Joined
Oct 8, 2004
Location
Woodstock, NY
TDI
Black '99 Jetta, Glacier Blue Audi 80 Quattro TDI
1. 1998 AHU crate engine with 12mm M-TDI pump into 1991 Audi 80 quattro
2. 9/25/12 driven daily
3. 34,000. 166,00 - 200200
4. oil leaks @ filter flange, crankcase breather. Vibration problems.
5. injectors brkng press. too high, gearbox gearing too low. Replaced injectors with Titans by franko6, and a proper TDI gearbox. Last 3 out of 6 tanks netted over 50mpg. Starts beautifully at -20º f. My favorite car I'll ever own.
http://www.motorgeek.com/viewtopic.php?f=6&t=45645&start=175
http://www.theprojectpad.com/viewtopic.php?f=11&t=1529&start=150
http://forums.tdiclub.com/showthread.php?t=344436
 

meby

Veteran Member
Joined
Sep 28, 2007
Location
Southwest Michigan
TDI
2000 Ford Winstar ALH TDI 5 spd
1. 2000 ALH 5spd in 2000 Ford Windstar
2. Date placed in service: Aug 2013
3. Miles/Kilometres rolled-up thus far: 36,000 miles
4. Minor issues: Misc electrical, popped intercooler boots, & terrible winter warm up times.
5. Major issues: Broke weld on axle
6. Link to your project:
http://forums.tdiclub.com/showthread.php?t=394424
https://www.facebook.com/FARMSHOWMagazine/posts/10153303585552164
7. Any other brief comments of interest (a couple of photos would be nice): Follow the links for pictures. Would do the swap again in a heartbeat!
 

Reddok

Veteran Member
Joined
Feb 18, 2010
Location
Hamilton, Ontario
TDI
'00 Jetta TDI 01M, '02 Jeep Liberty Renegade ALH TDI swap
1. 2002 ALH in 2002 Jeep Liberty
2. May 2011
3. 100,000km
4. Oil leaking into starter (Fixed oil cooler lines), chasing vibrations (new mounts)
5. Ate two DMF's. Found out flywheel wasn't centered on adapter - used runout gauge to correct and converted to SMF.
6. http://forums.tdiclub.com/showthread.php?t=291918
7. New swap project pending... Details soon.
 

otty

Veteran Member
Joined
Nov 7, 2010
Location
Revelstoke, BC
TDI
2003 Passat W8=>TDI swap, 4Motion Wagon, PD130(AVF) 6Speed Manual, 2006 Jetta MKIV PD(BEW) Wagon 5Speed Manual
1. 2003 AVF in a 2003 Passat W8 4motion 6 speed manual
2. March 2012 I bought the car freshly swapped
3. About 60,000km on it so far
4. Minor issues: still have some minor wiring issues but totally driveable.
5. Major issues in the past: cam, injector, tandem pump.
6. Not really my project. Bought it this way.

 

Lone Ranger

Veteran Member
Joined
Jul 13, 2007
Location
Winnipeg MB
TDI
TDI Ranger
-First was a 2001 ALH in a 1997 Ford Ranger(I believe I was the first one with a working TDI in a ranger in 2007, if not I'd like to be proven wrong)That one had about 300,000 km on it and ended badly due to failed lifters.

-Second and current one is a 2002 ALH in a 2005 Ford Ranger. This one was completed in August of 2012. It is currently 30,000km shy of 500,000 km
No major issues since I sorted all the bugs out with the first one.
minor stuff is everything you would expect with an ALH that has 750,000km on it(250,000 before install and 500,000 since)
 

oldpoopie

Vendor
Joined
May 14, 2001
Location
Portland Oregon
TDI
2001 golf gl, 2006 jetta, 1981 ALH swapped rabbit pickup, 1998 beetle
1. built ALH into 1981 rabbit pickup
2. first start July 5th 2015
3. 350
4. Exhaust leak, rusty fuel tank and bad fuel level sender, massive torque pulls control arms out of bushings.... Poly bushings fixed problem.
5. None so far
6. http://forums.tdiclub.com/showthread.php?t=419875
7. dont underestimate how a project like this will nickle and dime you. If you are looking for an economical swap, do it in a newer car. Mk1 parts can be tough to find. Also rust..... Found some big spots in the floor. :(
 
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TDIsyncro

Veteran Member
Joined
Nov 14, 2005
Location
Saskatoon, SK
TDI
Audi/TDI x 2
Lots of projects and changes in life since first swap so I am a little bit foggy on some of the exact dates and mileages. I think if there is one thing I can say about all of my swaps...I absolutely love the TDI engines. The torque and sound is near and dear to me. The great fuel economy is always the added bonus!


TDI Conversion No1
1. Engine and Vehicle installed - AHU in '93 Passat Syncro Sedan, Silver
2. Date placed in service - 2005 to 2008 (hit a deer and totaled it) :(
3. Miles/Kilometres rolled-up thus far - about 100,000km (?)
4. Minor issues - cold in cab in winter below -20C, constant electrical problems with lights, cluster, door handles were often a problem - no problems with motor
5. Major issues - none
6. Link to your project - no build thread
7. comments - best traction out of all my tdi projects...used it to pull my Audi A4Q through 2ft deep snow once.


TDI Conversion No2
1. Engine and Vehicle installed - AHU in ’92 Syncro (AWD) Wagon
2. Date placed in service - 2008
3. Miles/Kilometres rolled-up thus far - put on about 10,000km and sold it in 2009
4. Minor issues - cold in cab in winter below -20C, had minor brake drag on one wheel which turned out to be ABS controller problem
5. Major issues - none
6. Link to your project -
http://forums.tdiclub.com/showthread.php?t=260519
7. comments - super clean rust free body..was a very nice ride. The family that purchased it ended up hitting a deer about 6 months later and the car was totalled :( ...


TDI Conversion No3
1. Engine and Vehicle installed - BHW in 1999 Audi A4 Quattro
2. Date placed in service - Oct 2008, end of service - Oct 2011 (totaled in its prime! :mad:)
3. Miles/Kilometres rolled-up thus far - 150,000km (?)
4. Minor issues - never got cruise working..just never really tried to sort it out because I spent most of my time passing cars on highway anyways :D
5. Major issues - GTA2056V turbo went, turned out to be a screw on backing plate that backed out and put pressure on compressor wheel. Engine needed complete rebuild from this. :(
6. Link to your project
http://forums.tdiclub.com/showthread.php?t=212459
7. comments
loved loved loved this car! It was ultra smooth, quiet and dependable once I sorted out the vibration issues I had at the beginning. Great fun to drive. Great fuel economy. Excellent on ice and in snow.


TDI Conversion No4
1. Engine and Vehicle installed - 2009 CBEA CR Race engine in 2001 Audi A4
2. Date placed in service - still in very slow progress :eek:
3. Miles/Kilometres rolled-up thus far - about 2000km being towed from place to place :D
4. Minor issues
5. Major issues - no power :rolleyes:
6. Link to your project -
http://forums.tdiclub.com/showthread.php?t=270527
7. comments - life is full of unexpected changes. I have a long block ready. Lots of money spent, may be anouther $5K to still spend to finish this thing.


TDI Conversion No5
1. Engine and Vehicle installed - 2011 CJAA CR engine in 2007 Canyon
2. Date placed in service - just started
3. Miles/Kilometres rolled-up thus far - none
4. Minor issues
5. Major issues -
6. Link to your project -
http://forums.tdiclub.com/showthread.php?t=415533
7. comments - looking forward to a truck with great fuel mileage and that familiar TDI torque and sound..miss it!!



:eek:
 
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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
We need some more stories .........

My 84 Vanagon project is up to 57k miles since the maiden voyage in August of 2012. I'm planning to go over everything from Bumper to Bumper over the next couple of months in anticipation of another long road trip this summer.....
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis (where it's safe)
TDI
There are just too many to list....
We need some more stories .........

My 84 Vanagon project is up to 57k miles since the maiden voyage in August of 2012. I'm planning to go over everything from Bumper to Bumper over the next couple of months in anticipation of another long road trip this summer.....

Well I am just waiting for you to give me the go ahead to bring you another Vanagon for a conversion :p

Two, actually. One is a '91 and it already has an AHU bolted in, just need some help getting it to run... having some issues with the wiring.

The other is my '82, which is a natural-born diesel and is still complete, just need to find a good engine for it. I think I'd rather use an AAZ though. I like simple. :eek:
 

SVTWEB

Veteran Member
Joined
Aug 29, 2001
Location
Beyond Comprehension
TDI
2010 Jetta TDI Cup-Edition EVO 4-Motion
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