Time for an engine swap

[IronBenderII]

[Zeitgeist 13]

Just for clear comparison purposes, that's a brand-spankin' new engine there. Very few other engine swaps can boast that feature. I've dealt with enough FAS stuff to know they build really high quality items. I have no direct experience with those kits, but given all the other work I've seen from them, I have a high degree of confidence in their swap approaches.

I still suggest you try and find and drive an ABA, 1.8t and TDI van before settling on a swap, but if you are interested in mTDI, then perhaps you should contact Karl Mullendore about the pump work.
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Casey--

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

[IronBenderII]

Yeah, it looks like a beautiful kit. And I do like having the new engine (new everything really). I just don' know if I want to spend the $16k. Even though $$ was #20 on my list of critical factors, it is still a factor .
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FIRST Robotics Coach - #3859 (Wolfpack Robotics) http://www.twitter.com/wprobotics

'82 Diesel Westfalia with an 1Z TDI, Peloquin, GW 1.5" lift springs, 27" BFG ATs

'75 Bronco with 408 stroker, 40" MTRs, ARB/Dana 60 front/rear, all home built.

And my kid has a really cool baja bug

[torbot]

[Sassuan]

[888]

The PD link on that site was shut down by Firefox as unsecured so I can't see the detail.

This is the PD engine used on the late Mk4 early Mk5 cars or a different version?

[AndyBees]

The BEW (PD) engine come at about 130 hp stock. They were introduced here in NA, if I remember correctly, beginning with the 2004 model MK4s.

Early on, they had Cam Shaft issues related to the smaller lobes. The unit injectors are operated by cam lobes, thus, 4 extra lobes on the same cam. They required a particular spec oil. Seems the issue may have been solved with the BRM engines. I've done a TB job on one BEW engine .. that's about my experience with them.

Unless I totally missed it, the Oil Filter Housing on the BEW engine is located in the same place on the block as on the ALH engine .......... uses the same filter. So, how does FAS get that engine under an unmodified deck lid and have good ground clearance at the same time? I can drop my ALH about 1.5 inches and use the OE unmodified deck lid. I see no way to shave anything off the bottom end... seems the transmission would have to be lowered in the front to keep the 4 degree angle to the rear (VW spec).

Does anyone have a pic of the rear of a Van with one of these engines installed?
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'84 Vanagon Tin-top, ALH TDI. 1989 Tin-top
1983 Air-cool, 225k miles, 180k miles mine. Seven trips to Alaska from 1986 thru 2003.

[Zeitgeist 13]

I believe the PD blocks are essentially the same as the ALH. FAS builds their own oil pans, but I too had the same questions about that filter housing fitting under the decklid with stock ground clearance, wheel diameters and suspension settings.

Nowadays there's a remote filter housing adapter option, so that shouldn't be a problem with current 50 degree builds using the late model engine blocks.
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Casey--

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

[IronBenderII]

They must drop the whole motor and transaxle down.
_________________
FIRST Robotics Coach - #3859 (Wolfpack Robotics) http://www.twitter.com/wprobotics

'82 Diesel Westfalia with an 1Z TDI, Peloquin, GW 1.5" lift springs, 27" BFG ATs

'75 Bronco with 408 stroker, 40" MTRs, ARB/Dana 60 front/rear, all home built.

And my kid has a really cool baja bug

[AndyBees]

My first oil pan was a modified OE ALH aluminum pan. Working with my welder, we made it as close as possible as to the OE oil pan for the 1.6 Diesel Engine, i.e. it's relationship to the transmission (same level). I had extreme leak issues with that oil pan because of stress cracks along the welds primarily due to using aluminum stock that was too thin.

My second oil pan has the same configuration ..... level with the bottom of the transmission. It is stainless steel! Zero leak issues and no need for a skid plate, but I don't go off road anyway.

Yeah, I've seen the adapter plate for the remote oil filter. I've been working on a mod for that. Also, I've been tinkering with an ALH accessory bracket to modify the position of the Injector Pump...

Finding the time to do these things is the issue ..
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'84 Vanagon Tin-top, ALH TDI. 1989 Tin-top
1983 Air-cool, 225k miles, 180k miles mine. Seven trips to Alaska from 1986 thru 2003.

[888]

[Zeitgeist 13]

PD engines are a fairly popular swap for the off-road crowd, and I think they've long sorted out the cam and balance shaft issues. The common rails are becoming a popular swap now too. Both can be tweaked to produce massive amounts of torque. I'm contemplating either an ALH or PD swap in my Eurovan.
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Casey--

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

[r39o]

To the OP,

As stated it took me a long time (read years) to decide on my swap. The money part, complexity and long term service aspects with parts were the big things on my list.

When I did my swap, the cost of the used engine and various bits required to swap it in came to around $6K. (I think I got away kind of cheap.) Plus all sorts of extra stuff like transmission rebuild and cooling system were extra. Not to forget tire upgrade and brakes (and now front AC!) ADD to that all the TIME needed to get all the information and parts in one big pile. I am sure I spent the better part of a year getting everything lined up. In other words there is a LOT to be said for getting a complete package. Yes, 16K is a large sum. It depends on your goals. If money is #20 then I would strongly consider the FAS solution.

-W
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"Use the SEARCH, Luke" But first visit the Vanagon FAQ!

1990 Multivan EJ 22, Rancho trans 0.82 4th, Small Car front AC, CLKs w/ 215/65-16, homemade big brakes 303mm, Konis, Recaros, etc....

Click to see my ads for Cup holders, Subaru clutch fix and CLK wheels (no wheels currently)

[AndyBees]

FWIW, here are some pics when I was marking up my OE ALH TDI oil pan for modification to fit the 50 degree angle diesel set-up.

I feel certain the bottom end of the BEW and BRM engines use the same oil pump set-up as the ALH engine and most likely the same oil pan. So, as you can see from the pics, the oil pump sprocket is the "limiting factor" with respect to a "short" oil pan mod for additional ground clearance.

Note: all photos are with the engine hanging at a 50 degree angle.

The semi-circle is the approximate location of the oil pump sprocket..

Below, after the cut..

Below, is a view from the rear right side of the engine.

As I stated previously, this oil pan mod did not work out very well due to cracking along some of the weld seams. Thicker aluminum stock metal would have probably made the difference.
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'84 Vanagon Tin-top, ALH TDI. 1989 Tin-top
1983 Air-cool, 225k miles, 180k miles mine. Seven trips to Alaska from 1986 thru 2003.

[IronBenderII]

[syncrogreg]

Let me know if you need subaru diesel ee20 latest generation.

Greg
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conversions: www.boxeer.com Common rail TDI and NOW PDK transmissions!!

travel pictures:
http://instagram.com/crepeattack/

- the Pastis build: http://www.thesamba.com/vw/forum/viewtopic.php?t=434656&highlight=subaru+diesel

[IronBenderII]

Thanks. I think I decided against the Subaru engines. Too hard to find parts. You toasted a transaxle a while back, right?
_________________
FIRST Robotics Coach - #3859 (Wolfpack Robotics) http://www.twitter.com/wprobotics

'82 Diesel Westfalia with an 1Z TDI, Peloquin, GW 1.5" lift springs, 27" BFG ATs

'75 Bronco with 408 stroker, 40" MTRs, ARB/Dana 60 front/rear, all home built.

And my kid has a really cool baja bug

[IronBenderII]

Is the oil filter the only thing preventing an ALH mounted at 50* from requiring a raised deck lid? If I relocate the oil filter, can I keep my flat floor?
_________________
FIRST Robotics Coach - #3859 (Wolfpack Robotics) http://www.twitter.com/wprobotics

'82 Diesel Westfalia with an 1Z TDI, Peloquin, GW 1.5" lift springs, 27" BFG ATs

'75 Bronco with 408 stroker, 40" MTRs, ARB/Dana 60 front/rear, all home built.

And my kid has a really cool baja bug

[Zeitgeist 13]

I suspect that the filter housing and injection pump are the two biggest points of intrusion. Unfortunately if you want to go mTDI the pump will stick up slightly more than on an eTDI @ 50. This is my nearly complete ALH @ 15, which shows you how tall the pump is in relation to the filter housing. Mine fits under the lid.

_________________
Casey--

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

[888]