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Wed Jun 05, 2013 6:34 am

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I picked up a late 90's VW Engine code AHU 1.9 Tdi from a low mileage Passat..

From what I've read here on thesamba this was said to be a good candidate for a engine swap.

Just wanted to confirm that I'm picking up the right candidate, before I go back to get the engine?

I'm not going to run it on electronics, I already have several 1.6TD parts that I'm planning to use on the 1.9 engine, mechanical injection pump etc.

I would like to strip the engine down to as simple as possible and remove as much electrical clutter etc as can be done, but not sure what can be gone, or what must stay / replaced?

Not looking to make the engine a huge power plant, just perhaps a few tweaks to produce good mileage and a little more power & torque increase.

I didn't see much about AHU engine build threads, if I missed any of importance please direct me. But not sure if the AHU, engine varies from AAZ, ALH etc builds, there must be some differences? Are they apples, and Oranges, or similar? Guess the key is that I'm going mechanical and electrical ECU delete, am I doing the right thing?

What's the advantages, or disadvantages of this planned AHU 1.9 TD engine?

Any AHU engine builds Pics would be great.. 8)

I'm new to this Diesel stuff so, any helpful hint or suggestions would be greatly appreciated.

Thank you in advance for any helpful direction. :)
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Wed Jun 05, 2013 7:38 am

The AHU is a good candidate for a T3 Vanagon. You'll be able to use the factory 50 degree mounting bits. The left carrier and engine mount will need some work to clearance the turbo though. Also highly recommended that the turbo oil drain tube be plumbed into the oil pan- basically replicate what the factory did.

Running a 1.6L injection pump will produce mediocre results on a tDI. The 1.6s were IDI and run lower injection pressures than the younger brother DIs. Either plan to have a mTDI pump built or purchased or go through with the electronics install.

Another factor you've not mentioned is gearing. You'll want to consider re-gearing your trans for more friendly highway gearing.

There are numerous threads on here documenting all this. Plan to spend a good few hours reading. It'll answer many questions.

Good luck.

Rob

Wed Jun 05, 2013 7:58 am

AHU is an excellent engine choice for vanagon conversion. One of my vanagons has an AHU mTDI. The performance and fuel economy are excellent. You will want/need to regear the trans which is a topic all on it's own.

None of your 1.6 pump parts will be useful for running the engine. I can go into details but suffice to say it would be best to sell off any 1.6 pumps to help fund an actual properly built mTDI injection pump from a reputable builder (prothe isn't one...).

I also have a stock electronic TDI Jetta and have worked on several others. Owning and maintaining both electronic and mechanical TDIs I feel I am particularly well-suited for an objective answer to the benefits of either. The electronic engine management has many bells and whistles with being able to do data logging if you have VAG-COM ($300). It also gives the On-Board Diagnostics to assist in diagnosing the occasional problems that occur within the additional electronic parts that are not present and so cannot fail on the mTDI install. IMO you gain a very slight fuel economy benefit but the difference is slight enough that it is very hard to quantify (1%?). You will also have reduced NOx emissions with the eTDI. The electronic engine management has a reputation for reliability, but the slew of additional components that are not present on an mTDI result in many failure modes where the mTDI would not have been affected.

Wed Jun 05, 2013 9:00 am

Andrew..

First, I understand that the Trans gearing is another topic. I'll be picking the samba brain-e-acks for that data if and when I ever get that far..

So since you have experience with both eTdi, and mTdi are you saying that the eTdi is preferred?

Geeze thought that the MTdi would be more simple with less failures.

Also what is VAG-COM ($300).

I have also thought that the 1.6 TD mechanical Fuel Pump could be adjusted or sent out for Tweaks to perform well.. Noticed that there are a few 1.9 mechanical pumps available are they really different or 1 and the same as the 1.6 pumps?

The engine still has all of the stock electronics on it but I don't have the connectors that were on the car's wiring harness that connected to them, but may be able to get them and ECU if really needed or suggested?

Lastly, is it just me or are the Turbo's on these engines wee little ones, just seems like they should be upgraded to something larger like a T-3 kind of size? What would be a upgrade here?
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Wed Jun 05, 2013 9:19 am

The heart of both engines is the mechanical pump unlike the later common pump duse and common rail TDI's. So, both style pumps could experience a failure. For this discussion, I imagine an "E" pump would be more readily available in the VW dealer network if you needed one overnight which if you travel could happen. There are reputable shops selling adapted "M" pumps, but you would need to deal with them directly. A VW dealer might also be talked into working on your "E" TDI powered vanagon if needed since it is ODB II compliant.

I have over 25,000 miles with multiple cross country trips on our "E" powered TDI. I have found the additional electronic components to be very reliable. If others have been experiencing problems, I would be suspect of the wiring/install. That said, I was hestitant to do an "E" TDI conversion up front and was unaware there were "M" pumps available when I started the conversion. Not knowing what I know now and knowing what I did back then, I probably would have gotten an "M" pump. I also would have picked the earlier TDI. No regrets though.

Fri Jun 07, 2013 7:09 am

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WoW.. Things sound a little more complicated then I though Diesels were.

Thinking that I would still like to keep this build simple, kind of like old school seat of pants build. Kind of simple like the early 1.6TD's but with more power and grunt.

So here are my thoughts, please direct me if I'm going off a cliff.

Mechanical Fuel Pump.. :arrow: Perhaps Tweaked for better spray. Had though that the 1.6TD pumps could be worked, if not Which Pump, and any trusted builders?
Maybe some larger injectors. :arrow: Any Recommendations?
Prefer a Larger Turbo. :arrow: What's my choices or what needs to be done?

What has to happen with the AHU, Oil pan build, anyone building these?

I'm sure I'm missing a bunch so help save me from the Cliff.
Or what would you suggest on this Platform?
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Fri Jun 07, 2013 7:23 am

There are several reputable mTDI pump builders including myself, Karl Mullendore, Tintin on the GTD forum, Giles from Performance Diesel in Toronto, etc. You could also go the route of tracking down a VW LT 4-cyl tdi pump or a Land Rover 200TDI or 300TDI pump. The Land rover pump requires modification of the pump bracket.

All the stock 1.6 wiring and mounting parts, oil pan, etc will transfer over. The 1.6 flywheel/clutch is minimal. It will hold for stock AHU power, but even moderate performance improvements will slip it.

Even with stock injectors and stock turbo it will be waaayyyy more powerful than a 1.6 non-turbo.

Mon Jul 15, 2013 3:00 pm

I am just about to do the same sort of thing.

I recently bought a T3 motor home, which has an AHU fitted, but has a stock 1.6td JX pump & turbo on.

It is so bad on power & over heats on boost. It pisses oil out of the rocker cover & smokes on the exhaust. I did 30 miles & put it on a truck.

I have a Land Rover 200TDi pump coming & will either intercool or charge cool the turbo.

Does anyone know if the stock JX turbo will work ok, & what injectors are best?
Everything apart from the AHU block is 1.6JX & it's crap!

I have an Audi A4 as a daily driver with a stock AHU & can break that if I get really desperate, but I will have to find another daily.

I have some 9"x17" wheels coming to help with the gearing too.
It has a stock 1.6 JX gearbox fitted.

Mon Jul 15, 2013 9:27 pm

The JX turbo will work fine. It's a K14 and probably my favorite of the bolt-on wastegate turbos. You will want the AHU intake manifold as the ports are a different shape. The best injectors really depends on how much boost you are running.

Tue Jul 16, 2013 10:39 am

Cheers for that, it's good to know I can use some of it.

Boost is set at what ever they are supposed to run. I haven't touched it.

If the van makes 100hp, then that should push it up hills ok. I only want to cruze at 60mph.

Sun Jul 21, 2013 2:08 pm

I have spent a fair bit of time today investigating exactly what has been done.

It looks like the engine is a 1Y, which is a 1.9 non turbo diesel.
It has had the JX inlet manifold, which will have the wrong port shape & the exhaust manifold & turbo from a JX which could be used.
It has a non turbo fuel pump, so won't give enough fuel under boost.

It looks like I have a choice of replacing the pump & inlet manifold, or go right ahead with the TDi from my Audi...

Sun Jul 21, 2013 2:40 pm

If you have some 1.6 TD pumps,you can make your M-tdi pump easily.

1.6 body, guts from the Tdi, vertical lever to hydraulic head from a JX engine pump, and modify the horizontal lever at 17mm in the pump.Good to go.You will have to adjust the pump on the engine.

cheers

Sun Jul 21, 2013 3:04 pm

All I have is the 1Y non turbo pump & a Land Rover 200TDi pump.

Not sure which way to go now, a 1Y with a turbo is pretty much the same as an AAZ.

I might not have to break my Audi. If I do, I will have to fit the whole engine too.
That brings gearbox & clutch problems with it too.