TDI Conversion project success stories (short please)

[AndyBees]

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

 

[CFM]

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

 

[vwztips]

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!

 

[jimbote]

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

 

[oil_me]

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]

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]

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]

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]

-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)

 

[oilhammer]

This is an awesome thread. Great job, you guys!!!

 

[oldpoopie]

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.

 

[TDIsyncro]

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! )
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
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
3. Miles/Kilometres rolled-up thus far - about 2000km being towed from place to place
4. Minor issues
5. Major issues - no power
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!!

 

[jetmoto3]

1. 1z in 2000 dodge dakota
2. march 2015
3. 5000 miles
4. wiring of the brake switch caused limp mode
5. turbo seal went
6. http://forums.tdiclub.com/showthread.php?t=432609
7.

 

[samuraitd]

1. 1986 suzuki samurai, AHU with 2.8 mechanical injection pump
2. 3-2015
3. 10 lol
4. Needs exhaust
5. Head gasket failure, having problems keeping fuel system primed
6. http://forums.tdiclub.com/showthread.php?t=382153
http://bbs.zuwharrie.com/content/topic,125057.0.html
7. Will probably send this pump to Giles to have it rebuilt and tuned properly for my motor.

 

[ItAintRodKnock]

I see the nose of a gheenoe!!!!!!

 

[AndyBees]

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]

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

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.

 

[SVTWEB]

2001 Passat Wagon 4-Motion Automatic 2.8V6 Gasser...

Converted to 2001 Passat 4-Motion 6-Speed Manual, V6 TDI...

SVTWEB's B5 V6 TDI AWD:
Kick off: http://forums.tdiclub.com/showthread.php?t=69668
1/31/2004: http://forums.tdiclub.com/showthread.php?t=70195
4/10/2004: http://forums.tdiclub.com/showthread.php?t=75550
5/28/2004: http://forums.tdiclub.com/showthread.php?t=79496
6/19/2004: http://forums.tdiclub.com/showthread.php?t=80828
Completed: http://forums.tdiclub.com/showthread.php?t=82417
Driving Impressions: http://forums.tdiclub.com/showthread.php?t=98542