Everything needed for an AHU conversion

[OldBlueSyncro]

I know there's a lot of topics on these conversions, but I can't seem to find one that lists all parts needed for a AHU conversion.

If anyone could post a link to a thread on it, that would be greatly appreciated!

[MarkWard]

At the top of the vanagon forum, there is a FAQ thread. There is some information on diesel conversions, but there is not an exact thread for the AHU conversion. https://www.thesamba.com/vw/forum/viewtopic.php?t=402326
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[?Waldo?]

That's too broad of a question. There are many ways to do many parts of the conversion with upsides/downsides to each.

[MarkWard]

I notice your username has the word syncro in it. Are you asking about installing a diesel into a syncro? That is a more unique install vs converting a 2wd.
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[tjet]

I plan on doing a M-TDI swap in my syncro down the road. I bought a AHU swap take-out from a 1984 van, which consisted of a complete '96 Passat TDI engine, and all the specific parts off an original 1.6 Vanagon diesel (bellhousing, oil pump and pan, carrier bars, etc). The only unusual part is the exhaust manifold. It's off a Canadian AAZ diesel.

There a 2 ways to mount the AHU, at a 50 deg angle or 15 degree. I chose the 50 deg - same as a factory US spec vanagon diesel.

What I need to get is a special syncro only fuel tank, power steering pump, all the hoses and small parts, longer trans input shaft, and finally a modified M-TDI pump from a range rover.

I'm sure I will discover that I'm missing a bunch of other things once I start my conversion...

Note, you also need to budget in a transmission regear to match the TDI powerband. This would include swapping in a longer transmission input shaft.

FYI - this conversion will cost $7000 & up depending on your skill level.

[?Waldo?]

[OldBlueSyncro]

I realize now how broad of a question that is. Sorry about that. I just dumped a quick question on here before bed so that I would hopefully wake up to some responses.

I'll ask a few more precise questions:

1) If I sourced a stock diesel vanagon, the cradle bar/engine mounts would work for a 1.6d but will they work for all the td/tdi diesel engines? AAZ, AHU, ALH?

2) Since there's not many diesel syncro tanks out there, what options do I have with my stock gas tank? Would the kennedy 50deg bellhousing with that tdi starter adapter plate clear the tank?

3) How difficult is it to find one of these mtdi injection pump candidates? Do some of them require internal modifications?

At the moment I'm thinking of pulling the 1.6d out of my golf and putting it into my syncro since I'm having difficulty getting the wbx in there right now to even run right due to the PO's hack and slash job on the wiring. Then down the road I'll find a AAZ or AHU and put it in there.

[OldBlueSyncro]

I also realize how slow the 1.6d will be in a syncro, but I'm never in a rush when driving.

Reliability > Fuel Efficiency > Speed

I'm especially not in a rush when on a road trip and driving through some awesome scenery.

[tjet]

You need to ask yourself why you are doing the swap. Each of the engines you listed have their own pros & cons. The AHU & AAZ can be installed like the original diesel, but the AHU is more efficient from my understanding. The ALH is even more efficient, but is the most complex swap.

I do think your idea of finding a diesel donor van is a good idea, but not a requirement.

[OldBlueSyncro]

[?Waldo?]

[tjet]

[OldBlueSyncro]

[tjet]

If you get a donor van & go with a AHU, it's just of a matter of swapping things (exhaust may need some welding). The carrier bars may be an issue for a syncro as noted above.

[?Waldo?]

You could do the whole swap without any welding aside from the exhaust which you could have done at an exhaust shop.

[OldBlueSyncro]

[?Waldo?]

If you can't find the parts elsewhere for less, Quality German in Montclair probably has the syncro bars and even the syncro diesel fuel tank if you want to go that route.

Or if you prefer new, you can get them here: https://www.thesamba.com/vw/classifieds/detail.php?id=1861806

[MarkWard]

Look in the classifieds. There is a member making replica carrier bars including for the syncro. He also fabricates adapters for hydraulic mounts. If you want a syncro diesel tank, put a wtb add in the classifieds. That's how I got one for my project.
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