Build Thread: ALH into Bluestar @ 15 degrees

[Zeitgeist 13]

I like to face challenges, and/or create them via my pig-headed obstinacy, so I hereby offer this humble thread as an exemplar of my my preferred oeuvre.

My super reliable WBX is now spewing oil out of its long-suffering rear main seal, so I need to do something...anything. I choose to do what I had in mind way back when I bought this amazing van in 2004, and install a TDI engine. I just this very evening bought a nice 200k 2001 Jetta with an ALH auto. The engine pulls really strongly, but the auto trans is dying gracelessly. My plan is to install this engine @ 50 degrees, and to mate it to an automatic 3 speed transaxle, replacing the 4spd manual in there currently. Yes, I'm a glutton for gluten-free trauma. Stay tuned for more reality-based drama.

I should mention that I recently bought a TIG/plasma set, so the idea is to modify my existing '82 diesel install setup as much as required.




Note: I have shifted my approach by 35 degrees
_________________
Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[0cean]

Pictures are worth a thousand words. Let the surgery begin...

[Zeitgeist 13]

This is all you get, and you'll like it

_________________
Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[furrylittleotter]

Just cut the front off the car and weld it to the back of the Van. it will be far less painful than anything we are about to witness.

Have fun. This sounds like a really cool project to me, certainly worthwhile when all is said and done.

Neil

[Zeitgeist 13]

I honestly did consider a transverse install...really, I did.
_________________
Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[furrylittleotter]

I already have a fully converted suby and I am still considering cutting the front off the donor and welding it on next week.

I'd love to have a subaru automatic transaxle with all the factory wiring intact including cruise control. That'd be fun.

[xoo00oox]

Looking forward to watching this Zeit'

So, tell us more, what are your plans for gearing, oil pan, engine management?


Andrew-

[Zeitgeist 13]

Since you asked so nicely...

My current plan is to go eTDI, with the throttle/kick-down managed by the VW pedal or an MB unit sitting above the trans or just inside the engine compartment. The oil pan will either be a bastardized graft between the ALH and stock diesel unit, or a custom welded abomination. The engine mounting arms will be custom made and attached with Audi mounts to my '82 bars. The intercooler will either be stock or a Saab 900 unit mounted in the pillar with a small cooling fan. The transaxle will be a standard 3 speed with a 3.27 R&P and an external cooler with thermo-controlled fan.

I'm hoping that the sales of the excellent running WBX, manual trans and remaining Jetta body/parts will help defray much of the costs associated with the ALH install. I still need to acquire the auto parts and a Kennedy 50 degree adapter/flex-plate. Still not sure what to do about the tach.

I reserve the right to change my mind at any point in this process, because I'm a capricious mofo

_________________
Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[hans j]

I copied this for my tach http://www.brick-yard.co.uk/forum/lt-24-petrol-eng...tml#527970

And I used VAGdashCAN to turn my IMMO off. I have a friend with a full version but looks like you can buy Chinese knock-off cables for $150 on ebay. No idea if they will work!
_________________
1986 Canadian Syncro Westy TDI - 1989 Syncro Single Cab - 2001 Audi S4 - 1981 VW Caddy ABA - 1980 VW Caddy EV - 1973 VW T-181

[Zeitgeist 13]

Thanks for that link. Still not sure whether I should mod the stock T3 cluster or go wild weasel and just graft in the Jetta setup. Pic swiped from AndyBees' ALH thread at Fred's Haus of TDI:

Though, if you're going this direction, why not just use the Jetta light switch?
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[?Waldo?]

Regardless of which direction you take on this project I am sure that I will thoroughly enjoy watching it evolve.

I know, you said you're a glutton for punishment and still, I'll try talking sense. The ALH is an excellent engine. In all honesty, it is my favorite of ALL. All the changes they made from the AHU were good improvements. That said, the AHU will make the same power at the same fuel efficiency and is perfectly capable of transaxle destroying torque if that's your goal. More importantly the AHU and is much easier to install @ 50° (I know, you're a glutton...). The only performance improvement to the ALH is the VNT turbo and that is easy enough to fit to the AHU. If going with a 50° install I would go with the AHU. If you are bound and determined to go with an ALH, then the 15° install is easier. No need for a custom oil pan, the turbo will drain right, etc, etc... If you are mating the engine to the vanagon automatic, then you already need to use an adapter plate. Even at 50°, the ALH still won't fit under the engine lid and the bay bus bed hinges make the raised bed fully functional with the benefit of added storage. You're already planning on custom fabricating the mounting system. The vanagon diesel oil pump will not work. You won't be using the DV starter with the automatic. None of the diesel vanagon hoses work with the ALH. Basically NONE of the diesel vanagon parts will work without modification. What incentive is left for going with the 50° install other than the enjoyment of pain?

Just for reference:

My swap from my 1.6TD to my 50° mTDI AHU in my '83 took 2 weekends with most of the time spent remaking the exhaust.

My swap from the WBX to my 15° mTDI ALH in my '91 took 6 weekends. A significant amount of that time was dealing with non-drivetrain items including installing stainless coolant pipes, doing the rear brakes, cleaning the varnish out of the fuel tank and resealing it, installing the H4s with relays. I literally spent less time on my entire swap than AndyBees spent on just dealing with the oil pan issue.

I won't even touch the eTDI vs. mTDI subject...

And again, I'm eager to see this project unfold regardless of which direction you take on it.

[xoo00oox]

Zeit-

Make sure you save the starter from the Jetta, it will bolt up to your auto trans with no adapter just by making one of the mounting holes slotted.


Andrew-

[insyncro]

Very interested in seeing this unfold.

Thank you for sharing.

[Christopher Schimke]

I'm so excited...and I just can't hide it...you're about to lose control and I think I like it!
_________________
"Sometimes you have to build a box to think outside of." - Bruce (not Springsteen)

*Custom wheel hardware for Audi/VW, Porsche and Mercedes wheels - Urethane Suspension Bushings*
T3Technique.com or contact me at [email protected]

[TequilaSunSet]

[rubbachicken]

i am also looking forward to seeing this conversion unfold.
i think i can persuade mrs rubbachicken that this could be a good idea for her
_________________
lucy our westy

lucy's BIG adventure

meet 'burni'


markswagen {mobile mechanic} san diego area all early VW's cared for.

619 201 0310 or 617 935 4182

[Zeitgeist 13]

[svenakela]

A friend of mine took the time to swap from a AHU to a ALH. He did so many miles on that AHU you wouldn't believe it, but finally he got his hands on a ALH in mint condition so he took it. I don't know if he has any photos or how much time he put into the swap, but I do know that he is very satisfied with the new engine and the van is silent and very comfy.

I will make an ALH too if I get one before an AHU.

[Zeitgeist 13]

The victim:

Not bad for a 200k engine which has never seen major service

Sheesh, what kind of idiot swaps from manual to auto?

How difficult is it to kill the EGR without throwing a code? Can this be done DIY along with defeating the immobilizer? I'm currently absorbing the TDI FAQ so perhaps I'll settle on this info all by myself.

Yes yes, mTDI is the way to go, but I'm trying to do this on a strict budget, and a pump build blows the budget, especially since the 3.27 R&P is such a $$$-suck. I enjoy wiring projects, so I'm actually looking forward to the e-challenge
_________________
Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[?Waldo?]

That looks like 20° rather than 15°. At 15° the oil filter assembly appears to be vertical. @ 15° the high points on the eTDI are the EGR and the oil filler.

On my 15° mTDI I lifted the lid 3.5" but that is more than necessary and I didn't make any attempt to alter any of the components that I was using (oil filler cap, crank vent puck, etc). I could probably have gotten it down to 3" but that would have made the storage areas around the lid less effective and the use of the bay westy sofabed hinges harder. My mTDI also protrudes with the LDA on the injection pump, but that is not present on the eTDIs.

I have not done a 50° ALH but from the picture it looks like a smaller protrusion and that the major culprit is the oil filter housing cap and to a smaller extent the injection pump. Perhaps a lower profile cap could be used on the filter housing. Certainly a block-off plate and remote filter would be possible.