1986-1995 Toyota SR5 4WD to 1998 – 2003 Volkswagen 1.9L TDI
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Finally the power and economy you’ve been craving! DCS has taken into account all of the major steps and created a kit which contains all of the hard to manufacture & hard to configure parts. This kit is designed for the Toyota manual transmission ONLY.
A few things to consider before this conversion.:
Number 1, because this conversion package requires the transmission to be moved forward, the floor pan and potentially the lower portion of the dash will need to be altered to clear the shifter and you must weld the transmission mount bracket to the transmission crossmember.
Number 2--and this is a big one-- we do not at this time have wiring information for the truck side of these conversions. The wiring modifications available from DCS are for the VW engine only, you will be responsible for locating adequate power (key-on and 12volt supply), ground, instrumentation functionality, and determining how best to remove or modify the original Toyota EFI of the vehicle—including the Toyota fuel system, as ALH motors did not have a lift or electric fuel pump.
Number 3, for IFS trucks a significant (4.5 inch) lift is required to drop the front differential down enough to clear the oil pan of the TDI.
Number 4, The ALH was in different models of car in different years:
1998 through 2003 New Beetle
late 1999 (sometimes called '99.5) through 2003 Jetta sedan
2001 through 2003 Jetta Wagon (these are not called Sportwagon)
late 1999 through 2003 Golf
IFS (Independent Front Suspension) trucks require a 4 or 5 inch suspension lift that include a differential drop bracket. This is necessary to make room for oil pan clearance. DCS chose Rough Country for our lift kit and we are pleased with the fitment and quality of the components.
Engine Performance & Anti-Theft
Bypassing the Anti-theft with a “tune” is a must. You’ll also have the option of additional performance at the same time. It’s possible to utilize the VW instrument cluster however we chose to simplify the wiring to the greatest extent possible. When it comes to wiring less is best, in our opinion!
Transmission Adapter plate
Mates the engine and transmission with better than factory parts using aircraft quality 6061 aluminum. For correct starter engagement a crankshaft spacer is included. The crank spacer is important for proper clutch function as well. The Toyota starter is used with this application.
The engine mounts are designed to be bolt in replacement onto the VW engine and will bolt directly into the OEM Toyota isolators. A new set of engine isolators is included with the mounting brackets.
Fan shroud is made for use with a 14” electric fan of your choice. Please note that the fan must have the mounting brackets, or “flange,” on the outside edge of the fan.
Exhaust Down pipe flange
Often overlooked, the exhaust is long forgotten until you reach that step. A flange that bolts directly to the turbo charger, the rest is up to you.
One of the more time consuming parts of a project is mocking-up intercooler plumbing. Due to the variance in year / models we supply the bung to weld-in the Manifold Absolute Pressure (MAP) sensor.
Transmission Mount- Requires welding
The transmission mount will require the mount to be welded to the transmission cross member. You can use the mount as a template to cut into the cross member and then weld it together.
Steering Stabilizer relocation
This lowers the steering stabilizer for oil pan clearance. No holes to drill. This utilizes an abandoned hole in the front differential housing.
Drive shaft Spacer
The 1.75” spacer is necessary to lengthen the drive shaft to compensate for the forward movement of the transmission.
You will need a cowl hood to retain the EGR (Exhaust Gas Recirculation) Valve.