Look good! Thanks for sharing. I am just wrapping up my ALH swap info my old flatfender jeep. You are right! lots of little things you dont expect pop up.
Thanks for the info. Are you happy with your conversion adapters or do you think something like Cotybuilt truss for the engine would have been better? I am looking to build a TDI jeep soon, but I am worried about wiring, since I hate wiring and generally not that good at it. lol Great project! I am a huge fan of the LJ jeeps with the 6 speed standard trans.
I am happy with the conversion adapter because (1) it works (2) it was in my budget. If I had money falling out of my pocket I may have gone with the Cotybuilt, but who wants to bolt something together and have it work the first time? Where's the fun in that? If, you don't like wiring you could convert the ALH to a mechanical pump. There is a pump from a 4 cyl Land Rover that can be bolted on. Then you would just need a boost controller for the turbo or find a wastegated turbo. If I do another build I will go in that direction for simplicity in setup, maintenance and diagnosing.
The engine is installed with a slight tilt towards the firewall which makes the back of the head a low point. That is where the small coolant line comes out for bleeding the head. When I fill the coolant system I park facing down a steep hill so that the back of the head is now the high point in the coolant system. That gets the air out of the system and it starts to operate properly.
The tach runs off a pickup on the Jeep bellhousing. I threaded the Jeep oil sending unit in place of the VW one. Connected the Jeep alternator wired to the VW alternator. I used a coolant hose coupler with a sending unit port on the upper radiator hose for the Jeep water temp gauge. A 2 gauge pod sits on top of the dash holding the EGT and Boost gauges. The only thing on the Jeep cluster that doesn't work properly is the CEL. I also have a Scngauge II connected to the VW OBDII port.
I'm looking at doing this exact same setup in my 2000 TJ. First I just have to have a few questions confirmed about California smog laws, but then I'll be ready to start. I bought a 2002 Beetle ALH that I've been using as a daily driver to confirm that the engine is in good shape before starting the swap. I wish I could check yours out in person. The biggest question I have is: if you started over again what would you change about your install? Mounts? Wiring? Turbo piping setup? Or would you still do this swap at all? Thanks!
I'm getting ready to redo the mounts. I would like to neaten up the hoses and wiring. I am glad I did the swap. Dont do it as a money saver. Do it because you want to.
Boyd thanks so much for the reply. Ya it will cost a lot but I think it makes sense for me. 1. I'd be replacing a tired 2.5L so the power/torque will be very nice. 2. The mpg will be nice from a range perspective, I often spend time in remote places like Death Valley. 3. This jeep will be in our family forever, so having the long-term reliability and long-term savings on fuel are added bonuses. Did you ever consider going for the HPA/Coty truss/mount? It's super pricey but I do like how it keeps most of the jeep accessories.
did you ever figure out what was causing the starter soleniods to go bad, or find a better quality one? i'm shopping for an adapter but dont want to buy one thats eats starter soleniods all the time! ive got my eye on different adapter that uses a vw starter.
I found a starter from Jegs that is the same. Hopefully it is better quality. The biggest issue is heat. The downpipe is right beside the starter. I have wrapped the downpipe and made a heat shield for the starter.
Look good! Thanks for sharing. I am just wrapping up my ALH swap info my old flatfender jeep. You are right! lots of little things you dont expect pop up.
Thanks for the info. Are you happy with your conversion adapters or do you think something like Cotybuilt truss for the engine would have been better? I am looking to build a TDI jeep soon, but I am worried about wiring, since I hate wiring and generally not that good at it. lol Great project! I am a huge fan of the LJ jeeps with the 6 speed standard trans.
I am happy with the conversion adapter because (1) it works (2) it was in my budget. If I had money falling out of my pocket I may have gone with the Cotybuilt, but who wants to bolt something together and have it work the first time? Where's the fun in that? If, you don't like wiring you could convert the ALH to a mechanical pump. There is a pump from a 4 cyl Land Rover that can be bolted on. Then you would just need a boost controller for the turbo or find a wastegated turbo. If I do another build I will go in that direction for simplicity in setup, maintenance and diagnosing.
Did you have to move the transmission forward for firewall clearance? Are you still using the VW vacuum pump?
Very nice job!! How did you connect the engine to the transmission? Thanks.
+a154610
I bought an adapter from these guys...
gastodiesel.tdconversions.com
Looks good! You should look up "tdi swapped trucks" on Facebook and share. I'm planning on doing an alh swap to a 4runner soon hopefully.
Great video Boyd. Did you have issues getting heat. We’re having some coolant issues but maybe it’s an air pocket like you say.
The engine is installed with a slight tilt towards the firewall which makes the back of the head a low point. That is where the small coolant line comes out for bleeding the head. When I fill the coolant system I park facing down a steep hill so that the back of the head is now the high point in the coolant system. That gets the air out of the system and it starts to operate properly.
What did you do for gauges? Where you able to wire in the factory jeep gauges?
The tach runs off a pickup on the Jeep bellhousing. I threaded the Jeep oil sending unit in place of the VW one. Connected the Jeep alternator wired to the VW alternator. I used a coolant hose coupler with a sending unit port on the upper radiator hose for the Jeep water temp gauge. A 2 gauge pod sits on top of the dash holding the EGT and Boost gauges. The only thing on the Jeep cluster that doesn't work properly is the CEL. I also have a Scngauge II connected to the VW OBDII port.
I'm looking at doing this exact same setup in my 2000 TJ. First I just have to have a few questions confirmed about California smog laws, but then I'll be ready to start. I bought a 2002 Beetle ALH that I've been using as a daily driver to confirm that the engine is in good shape before starting the swap. I wish I could check yours out in person.
The biggest question I have is: if you started over again what would you change about your install? Mounts? Wiring? Turbo piping setup? Or would you still do this swap at all?
Thanks!
I'm getting ready to redo the mounts. I would like to neaten up the hoses and wiring. I am glad I did the swap. Dont do it as a money saver. Do it because you want to.
Boyd thanks so much for the reply. Ya it will cost a lot but I think it makes sense for me. 1. I'd be replacing a tired 2.5L so the power/torque will be very nice. 2. The mpg will be nice from a range perspective, I often spend time in remote places like Death Valley. 3. This jeep will be in our family forever, so having the long-term reliability and long-term savings on fuel are added bonuses.
Did you ever consider going for the HPA/Coty truss/mount? It's super pricey but I do like how it keeps most of the jeep accessories.
I considered the Coty mounts but 2 things stopped me. The price and someone at Coty said it would not work with my ALH.
did you ever figure out what was causing the starter soleniods to go bad, or find a better quality one? i'm shopping for an adapter but dont want to buy one thats eats starter soleniods all the time! ive got my eye on different adapter that uses a vw starter.
I found a starter from Jegs that is the same. Hopefully it is better quality. The biggest issue is heat. The downpipe is right beside the starter. I have wrapped the downpipe and made a heat shield for the starter.
@@ANNEBOYD23 TD Conversions did change to a better US made Powermaster starter in 2018. Much more reliable. Nice swap!
AC is not necessary. My Jeep doesn’t have one. Though I do live in Maine. Heat is not to bad.
+Jeremy Rhodes
I can survive without it. My wife would really like to have it.
looks great, any clearance issues??
The only clearance issue is the A/C compressor over the front differential. I had to remove it and make a small idler. I'll have more details later.
@@ANNEBOYD23 appreciate the reply, just curious did you ever consider the aaz mechanical engine?
Dan Mccarthy I already had the ALH. If I were to do it again I would definitely look at other options.
What is the mpg?
28 mpg on the highway. 22 mpg towing my work trailer. The best I've done is 36 mpg cruising at 55 mph.
Boyd how heavy is the work trailer? Can you drive 70 with the trailer?
Did you have to move the transmission forward for firewall clearance? Are you still using the VW vacuum pump?
No I did not. Using the Gas to Diesel Conversions adapter allowed for me to keep the stock vacuum pump and clear the firewall.
Thanks Boyd!