Zeke Gets a TDI Swap (VW Mk4 1.9 ALH Manual). (3 Viewers)

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New stand alone wiring harness arrived today, together with a reconditioned ecu with the immobilizer decommissioned. Stoked!

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Go get @Old Nick
I've been reading in a lot a different forums. The bug's set-up (even though the engine is the ALH) is different. Supposedly, I'm supposed to avoid it... lol. Thank you for the heads up!
 
There are certainly a lot of differences between the Beetle and the Jetta/Golf, but those are primarily body and electrical differences. If you already have a wiring harness and ECU for that year the engine itself will work just fine. A few of the accessories might be a little different, but nothing springs to mind apart from the turbo support bracket. Being a 2001 model the engine wiring will be a little different from the 2002-2003 models, for instance the glow plug harness runs 4 wires instead of 2 and the ECU coding is a little different to help with glow plug control and diagnostics. @2gbFlashDrive is doing an LJ73 TDI swap using a Beetle engine, I haven't come across anything yet that is markedly different than on my Golf engine.

I would hold out for an automatic version, they came with the 11mm injection pump instead of the 10mm version used on manual transmission cars, which means one less thing to upgrade in order to achieve your power goals. The auto transmissions tended to give out pretty easily in the diesels, shouldn't be too hard to find one with a blown transmission for cheap.
 
There are certainly a lot of differences between the Beetle and the Jetta/Golf, but those are primarily body and electrical differences. If you already have a wiring harness and ECU for that year the engine itself will work just fine. A few of the accessories might be a little different, but nothing springs to mind apart from the turbo support bracket. Being a 2001 model the engine wiring will be a little different from the 2002-2003 models, for instance the glow plug harness runs 4 wires instead of 2 and the ECU coding is a little different to help with glow plug control and diagnostics. @2gbFlashDrive is doing an LJ73 TDI swap using a Beetle engine, I haven't come across anything yet that is markedly different than on my Golf engine.

I would hold out for an automatic version, they came with the 11mm injection pump instead of the 10mm version used on manual transmission cars, which means one less thing to upgrade in order to achieve your power goals. The auto transmissions tended to give out pretty easily in the diesels, shouldn't be too hard to find one with a blown transmission for cheap.
Thank you, brother.

I got some time to work on this today…

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I can probably DHL you a VDub 1.9L from ZA if you want...

:flipoff2:
 
There are certainly a lot of differences between the Beetle and the Jetta/Golf, but those are primarily body and electrical differences. If you already have a wiring harness and ECU for that year the engine itself will work just fine. A few of the accessories might be a little different, but nothing springs to mind apart from the turbo support bracket. Being a 2001 model the engine wiring will be a little different from the 2002-2003 models, for instance the glow plug harness runs 4 wires instead of 2 and the ECU coding is a little different to help with glow plug control and diagnostics. @2gbFlashDrive is doing an LJ73 TDI swap using a Beetle engine, I haven't come across anything yet that is markedly different than on my Golf engine.

I would hold out for an automatic version, they came with the 11mm injection pump instead of the 10mm version used on manual transmission cars, which means one less thing to upgrade in order to achieve your power goals. The auto transmissions tended to give out pretty easily in the diesels, shouldn't be too hard to find one with a blown transmission for cheap.
Man, I'm on the hunt.

I'm not sure if you'll know the answer to this, but thought I'd put it out there just in case... would you happen to now if the German engine code (AHF the 110hp Euro version of the ALH) uses the same wiring harness as the U.S. spec ALH? The German coded engines are somewhat stripped down from what I gather... no EGR. And, its internals are supposed to be a bit more robust. They are priced about 10-15% more than U.S. spec ALHs

Heck, I should just stick with the U.S. ALH and spend that 10-15% on upgrading... lol.
 
Nice looking battery tray. Sorry; wrong thread. 😁
I had that battery talk in th back of my mind, because Zeke's battery tray does in fact have a rubber covering over it. Sure looks like a factory coating.
 
That brings back flashbacks. Like when I replaced #5 exhaust valve and broke a rib by leaning too hard against that fender seam.

It's fun to see it getting stripped down to see what you discover
No broken ribs yet (thank goodness), just a couple of bloody knuckles so far. Most of the bolts in the engine bay are coming out smoothly. But, there is one bolt on the air filter cap... right up by the firewall that is giving me fits... lol. It's the only rusty one. The others came right out. I may need to slip a sawsall between the upper and lower filter housings to get that one off... lol.
 

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