Author Topic: M-TDI ALH into a MK2 swap  (Read 1575 times)

November 17, 2019, 03:43:51 pm

fatmobile

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M-TDI ALH into a MK2 swap
« on: November 17, 2019, 03:43:51 pm »
 I have an ALH engine, a '91 Golf and a pump.
 Starting with the clutch so I can make some timing marks for TDC and 12BTDC.

I'm going to use the MK2 020 trany to start with and upgrade to the TDI trany later, just to get it on the road faster and have it running while I collect the parts for an 02A or J
 Should I use the MK2 tin clutch cover or the TDI style?


 If I use the MK2 tin covers I'll need to use the MK2 crank seal carrier,
because the MK2 tin bolts to it.


Also wondering what to do on the other end with the serpentine belt.
 Since I don't want power steering or AC.
tdifrontbelts by vwfatmobile, on Flickr


Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #1November 20, 2019, 04:35:18 pm

libbydiesel

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Re: M-TDI ALH into a MK2 swap
« Reply #1 on: November 20, 2019, 04:35:18 pm »
I haven't specifically done the ALH -> Mk2 with 020 trans so I'm not sure about the intermediate plate.  I think the mk2 plate and seal carrier would work. 

For the serp belt, it seems to me that you could just get the right length belt so it wraps just the crank and alt and Bob's your uncle.

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Reply #2December 21, 2019, 07:41:00 pm

fatmobile

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Re: M-TDI ALH into a MK2 swap
« Reply #2 on: December 21, 2019, 07:41:00 pm »
Thanks Andrew, this engine didn't come with a serpentine belt tensioner.
And there are a couple other things I need to get from the guy the engine came from.
I'll figure out the proper length for the belt.
 That picture is a great help.
 
 I also decided to use the MK1 intermediate plate under the clutch.
 Even though the TDI seal carrier didn't have the 3 mounting holes I kept it.
 I think when the trany is bolted on,
 it will hold the tin down tight enough to keep it away from the pressure plate
and tight against the seal carrier.
 It just looked so dry around the seal I didn't want to mess  with it.
« Last Edit: December 22, 2019, 05:35:06 pm by fatmobile »
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #3December 23, 2019, 09:06:30 pm

fatmobile

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Re: M-TDI ALH into a MK2 swap
« Reply #3 on: December 23, 2019, 09:06:30 pm »
  Andrew you suggested I get a new tensioner.
 Did you mean a whole tensioner or just a new pully/idler?
Also wondering; do you know if the tensioner pully and 3 mounting bolts are TTY and need to be replaced with new ones.

 Edit:
 After some searching I never saw it mentioned that the 3 mounting bolts are TTY and need replaced. Just that they need torqued to 18ftlbs.
« Last Edit: December 24, 2019, 11:09:43 am by fatmobile »
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #4December 24, 2019, 11:47:53 am

libbydiesel

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Re: M-TDI ALH into a MK2 swap
« Reply #4 on: December 24, 2019, 11:47:53 am »
I was talking about this whole unit:  https://www.idparts.com/serpentine-belt-tensioner-a4-alh-p-629.html

I have not seen just the pulley/bearing offered aside from the entire unit.  If you find that available let me know.  I don't think the bolts are TTY.
Use, abuse or ignorance of any information is at your own risk, confirmation or refutation is your own responsibility, no further 'proof' will be given, take it or leave it, YMMV,terms subject to change without notice, avoid contact with eyes or skin, contents known to cause cancer in California

Reply #5December 24, 2019, 12:00:43 pm

fatmobile

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Re: M-TDI ALH into a MK2 swap
« Reply #5 on: December 24, 2019, 12:00:43 pm »
Here's just the idler pully:
https://www.idparts.com/serpentine-belt-relay-rolleridler-pulley-a4-alh-p-452.html
 About half the price.
autohaus and rock auto have them for $25 for contitech or INA
 Still think the whole tensioner needs replaced?
  These TDIs are sure more expensive to maintain than the IDIs.
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #6December 24, 2019, 12:23:48 pm

libbydiesel

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Re: M-TDI ALH into a MK2 swap
« Reply #6 on: December 24, 2019, 12:23:48 pm »
That's not the tensioner pulley.  If you look at the prior posted image of the belt system that is the idler that is below and a little to the right of the alternator pulley.  That isn't needed if you plan on running just the alt with a shorter belt. 
Use, abuse or ignorance of any information is at your own risk, confirmation or refutation is your own responsibility, no further 'proof' will be given, take it or leave it, YMMV,terms subject to change without notice, avoid contact with eyes or skin, contents known to cause cancer in California

Reply #7December 24, 2019, 12:32:19 pm

libbydiesel

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Re: M-TDI ALH into a MK2 swap
« Reply #7 on: December 24, 2019, 12:32:19 pm »
If money is tight and you can get a used tensioner and the pulley spins well then it is worth considering.  If it fails and shreds the belt like mine did, it isn't all that big of a deal.  The water pump is driven by the timing belt so if the serp belt fails you can continue running without endangering the engine. 
Use, abuse or ignorance of any information is at your own risk, confirmation or refutation is your own responsibility, no further 'proof' will be given, take it or leave it, YMMV,terms subject to change without notice, avoid contact with eyes or skin, contents known to cause cancer in California

Reply #8December 24, 2019, 07:55:57 pm

fatmobile

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Re: M-TDI ALH into a MK2 swap
« Reply #8 on: December 24, 2019, 07:55:57 pm »
Oohh, thanks.
 I would have bought a useless idler.
 
 The shock on the tensioner I got,
 from the guy I got the engine from
 feels weak too.
 I'll see if he has another one that's in better shape.
 If not I might need a whole new tensioner.
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #9February 22, 2020, 01:45:26 am

fatmobile

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Re: M-TDI ALH into a MK2 swap
« Reply #9 on: February 22, 2020, 01:45:26 am »
 I got a new tensioner and the belt I used for the AC/PS delete was
Gates belt part number K060295.
 I installed the tensioner after the engine was in.
 I had to pull the pin and release it before install or the pin would hit the frame.

 The VNT-15 didn't work with the stock MK2 rear mount so I made one that dodged under it.


 Plenty of room for exhaust from the turbo.
 But the stock TDI downpipe runs too far to the p-side.

A little off center and angled slightly wrong. I'll have to make my own.
It's 2" pipe coming from the turbo.
MTDIstockexhaustoffcenter_2 by vwfatmobile, on Flickr



Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #10February 22, 2020, 12:03:14 pm

libbydiesel

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Re: M-TDI ALH into a MK2 swap
« Reply #10 on: February 22, 2020, 12:03:14 pm »
I look forward to seeing more.  :)
Use, abuse or ignorance of any information is at your own risk, confirmation or refutation is your own responsibility, no further 'proof' will be given, take it or leave it, YMMV,terms subject to change without notice, avoid contact with eyes or skin, contents known to cause cancer in California

Reply #11March 05, 2020, 10:53:42 pm

fatmobile

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Re: M-TDI ALH into a MK2 swap
« Reply #11 on: March 05, 2020, 10:53:42 pm »
 Some more progress:
  I got the turbo downpipe done.
 Along with the turbo to intake pipework.
 The turbo to intake pipe was made with a piece of 1.5" ubend.
 I cut it straight down the middle and turned the ends to line up with the turbo outlet and the intake.

The silicone coupler with the 90 is a 1.5" to 2"adapter:
https://www.ebay.com/itm/1-5-to-2-38-51mm-Silicone-90-Degree-Elbow-Reducer-Intercooler-Coupler-Hose/163749999543?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m2749.l2649
 I'm connecting it to the barbed fitting on the thingy that bolts to the stock intake.
 Because it provides some runaway protection by closing the flapper.

 The exhaust was made with scrap stainless I got years ago from some pipefitters,..
 pulled from a pudding line.
 I welded it with my mig welder, stargon and stainless .023 wire. It worked.
 
 The flex piece:
https://www.ebay.com/itm/2-X-6-SS409-EXHAUST-FLEX-PIPE-2-00-X-6-00-2-X6-HEAVY-DUTY/223733712652?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m2749.l2649
 goes from the stock 2" 90 to the 2.5" stainless pipe.
 I had to cut the stock 90 and line it up better.
 The 2" stock piece fit inside, and the thickwall 2.5" stainless fit noicely around the other end.
 The rest of the exhaust was 2.5" from the stock 1.6 turbo setup it had before.
 
 Picture of inside the turbo can.
 The cup needs to face this way so it can sink into the recess in the top.


 I'll post some pictures of the pipes in place,..
and a picture of the car but this is a post about putting an MTDI in a MK2.
 It this isn't going to turn into a post about tires/rims,body work and suspension.
 I can hardly wait to drive this thing. I'm buying a wrecked '98 TDI for the trany stuff and rear support.
But I'm going to get it running with the 020 first.
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #12March 07, 2020, 11:07:10 pm

fatmobile

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Re: M-TDI ALH into a MK2 swap
« Reply #12 on: March 07, 2020, 11:07:10 pm »
 The accelerator cable is tight.
 Just a little short.
 I wonder if the MK3 AAZ cable is longer.

 I don't know much about the TDIs.
 Going to have to take a look in the engine bay of one to figure some of this out.

 There is a hose coming off the end of the head,..
 near where the heater hose comes out.
Probably a 3/8" tube.
 What is that?
 A coolant/air drain from the top corner of the head?
 Pipe it into the reservoir?

 I'll need to get some plugs for sensors and alternator.
 I wonder how those will work with the dash.
 Which sensor is for the dash temp gauge?

 Glow plugs have a manual button, ford starter solenoid.
 Wired it up to a stock TDI glow plug buss.
 
Wired up the  injection pump.
 Put a blade on the pump, Mk2 style.

 Most of the MK2 coolant hoses are lining up nicely.
 One extra 5/8" port pointing out the front of the engine.
 I'll have to figure out how to plug that.

 Vacuum hose from the pump to the booster is going to have to be short and bendy.
Practically and S curve.
Wonder what the TDI one looks like.
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #13March 08, 2020, 12:00:40 am

libbydiesel

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Re: M-TDI ALH into a MK2 swap
« Reply #13 on: March 08, 2020, 12:00:40 am »
The small hose coming off the head is an air bleed.  Yes, route it to the reservoir. 
Use, abuse or ignorance of any information is at your own risk, confirmation or refutation is your own responsibility, no further 'proof' will be given, take it or leave it, YMMV,terms subject to change without notice, avoid contact with eyes or skin, contents known to cause cancer in California

Reply #14March 25, 2020, 11:32:21 pm

fatmobile

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Re: M-TDI ALH into a MK2 swap
« Reply #14 on: March 25, 2020, 11:32:21 pm »
Got the turbo to intake pipe installed.
 Along with the airbox to turbo plumbing.


I'm using the MK2 airbox.
 It's 2 3/4".
I used this one to go from 2 3/4"down to 2"
https://www.ebay.com/itm/Silicone-45-Degree-BOV-Reducer-Elbow-Hose-51mm-70mm-2-2-3-4-2-75/202792017449?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649
I think I removed 1 3/4" from the 2" end.

 The turbo input is 1 3/4"
I used this 45 degree elbow to go up to 2" from 1 3/4".
https://www.ebay.com/itm/1-75-2-45-DEGREE-REDUCER-4-PLY-RED-SILICONE-HOSE-INTAKE-TURBO-TUBE-COUPLER/182387132762?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649
Had to cut a little off to get it back from the frame.

I had a piece of 2" scrap stainless with a bend that went between the 2.
 It will also have a pipe for the PCV hose,.. a piece of 3/4" silicone radiator hose.

Onto the cooling system.
 The upper radiator hose for the MK2 was a little short.
 I bought this piece:
https://www.ebay.com/itm/Gates-Rubber-Products-21703-Upper-Radiator-Hose-12-Month-12-000-Mile-Warranty/143207347269?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649
and used the 180 from the upper radiator port (1 1/4").
 The stock hose shrinks down to 1 1/8" away from the end.
 So I had to find a 1 1/4" to 1 1/8" adapter to splice them together.
https://pay.ebay.com/rxo?action=create&rypsvc=true&pagename=ryp&item=292873093554&transactionid=-1&quantity=1&var=591642912683&rev=1&rsp=true

The small line coming from the injectors is plumbed into the 1/4" line heading back to the tank through one of these:
https://www.ebay.com/itm/1-4-X-1-8-HOSE-BARB-TEE-Brass-Pipe-3-WAY-T-Fitting-Thread-Gas-Fuel-Water-Air/171988984668?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

Pretty tight fit with all this piping but they clear the frame and each other nicely.
I'll get a better picture,.. maybe from underneath.
 The exhaust pic just looks like an exhaust pic so I didn't post it.
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block