diesel conversion....
Mountain Pass
Joined: Oct 2002
Posts: 205
Likes: 0
From: Jaqcksonville
Been away for a while. Pablo The engine Fwd or Rwd will not be an issue. The motor will fit with new mounts. My trans mission choice is an older a4ld with cable throttle valve or Zf4hp22 from a lincoln diesel. These two transmissions have removable bell housings which give starter location options. I cant use the vw starter as it mounts from the back of the engine. I will make an adaptor plate that will go to the back of the motor. Use the vw flexplate or flywheel and bolt a starter ring gear flexplate to the flywheel. The starter non vw will bolt to the new adaptor plate. I am removing the excess circuits from the wiring harness at the minute as the injection pump is electronic and uses drive by wire. If this set up turns out to me to much of a mess I will get a land rover 200 tdi injection pump and will only need 1 wire to the stop solenoid. The Ford Galaxy thoug smaller than the Aerostar is a beautiful machine plenty of pep and great gas mileage.
Thread Starter
|
Post Fiend
Joined: Oct 2005
Posts: 5,242
Likes: 0
From: Kiev, Ukraine
anyway you will make a plate to fit VW engine to ford tranny. Why do you think Ford make bellhousing for WV? It is not heavy duty truck, all class 6, 7 and 8 engines and trannies fit each other (ha ha but not clutch kits), but no ford bellhousing fits VW bolt pattern, so look for diesel engine and tranny together... BTS Mitsubishi L200 diesel engine and tranny fit aerostar
Mountain Pass
Joined: Oct 2002
Posts: 205
Likes: 0
From: Jaqcksonville
The adaptor will bolt to the vw engine block. The trans bell housing bolt pattern will be transferred to the adaptor and the plate tapped for bolts. it doesnt matter what trans is useb providing the flywheel/flexplate and starter . clearances etc will hjave to be met. this will determine the adaptor thickness etc.
Mountain Pass
Joined: Jan 2008
Posts: 193
Likes: 0
That VW conversion sounds awesome jetfire. Sounds like you know what you're doing, is there anyway you can post some pics of your conversion? I'm thinking of doing something similar with my 3.0 eventually. Thanks...
Thread Starter
|
Post Fiend
Joined: Oct 2005
Posts: 5,242
Likes: 0
From: Kiev, Ukraine
IMO: You've choosen the difficult way of conversion.
1. To make the conversion plate to fit A4LD is not so easy, TC will not fit manual tranny flightweel and you will have additional pain (
2. OD and TC Clutch are electronically controlled in A4LD, how will you controll them?
3. You are going to use FIP cabel position to get engine load, becouse you cant use vac. modulator with diesel. Belive me shift points will not be optimal.
4. Mechanical pump is not so accurate as EDC and ypu will have fixed injection timing, not variable as with EDC. Why not to use VW EDC with computer? You will loose 20-25% of HP and MPG.
Why not to find RWD powertrain? Engine and Tranny? There are small Mercedes, Cummins and Perkins engines (i do not say about duratorq of EU ramger) that fit Aero easily. Well, CRD Cummins B series with Allison tranny will be the best but the expensive solution. May be there is a reason to get 5 ore 6st manual tranny... More perfomance, more MPG!
1. To make the conversion plate to fit A4LD is not so easy, TC will not fit manual tranny flightweel and you will have additional pain (
2. OD and TC Clutch are electronically controlled in A4LD, how will you controll them?
3. You are going to use FIP cabel position to get engine load, becouse you cant use vac. modulator with diesel. Belive me shift points will not be optimal.
4. Mechanical pump is not so accurate as EDC and ypu will have fixed injection timing, not variable as with EDC. Why not to use VW EDC with computer? You will loose 20-25% of HP and MPG.
Why not to find RWD powertrain? Engine and Tranny? There are small Mercedes, Cummins and Perkins engines (i do not say about duratorq of EU ramger) that fit Aero easily. Well, CRD Cummins B series with Allison tranny will be the best but the expensive solution. May be there is a reason to get 5 ore 6st manual tranny... More perfomance, more MPG!
Mountain Pass
Joined: Jan 2008
Posts: 193
Likes: 0
Hey Pablo what are these perkins and cummins motors you are talking about? What kind of horsepower do they have and how much do they weigh? And are you sure they're available in the states? We don't have many small diesel powered cars and trucks here in the states, most smaller vehicles are gasoline powered. I know the 5 cylinder mercedes engines are available in the Dodge sprinter vans, but they are expensive. A rebuilt mercedes engine usually sells for around $10K+. I have a perkins diesel (4.236) in my backhoe (JCB) and it's an awesome motor. But I think it only has 80hp and is pretty heavy by automotive standards.
Mountain Pass
Joined: Oct 2002
Posts: 205
Likes: 0
From: Jaqcksonville
The only widely available light weight up to 5k rpm diesels in the US are the Vw 1.9tdi or later 2.0 tdi. Yes there are others however regarding the vw parts are available and there is so much information available and proven regarding nozzle changes chipping etc. A quick search shows the VW diesel users are a passionate bunch like Aerostar owners. Ive had and am familiar with Perkins. The problem with them is that they are designed for heavy, stationary, and movable equipment have lots of torque but very low rpm operation and are a product of 50s and 60s design using rope seals etc. Great engines but very heavy. The perkins prima 2.0 a later engine would be a good conversion canditate, but again hard to find.
FTE Stories
Ford Trucks for Ford Truck Enthusiasts
10 Best Ford Truck Engines We Miss the Most!
Joe Kucinski
2026 Shelby F-150 Off-Road: Better Than a Raptor R?
Brett Foote
2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!
Michael S. Palmer
10 Most Surprising 2026 Ford Truck Features!
Joe Kucinski
Top 10 Ford Trucks Coming to Mecum Indy 2026
Brett Foote
5 Best / 5 Worst Ford Truck Wheels of All Time
Joe Kucinski
Ford Super Duty: 5 Things Owners LOVE, 5 Things They LOATHE!
Joe Kucinski
Every 2026 Ford Truck Engine RANKED from WORST to FIRST!
Michael S. Palmer
The Best F-150 Deal of Every Trim Level (XL through Raptor)
Joe Kucinski
Mountain Pass
Joined: Oct 2002
Posts: 205
Likes: 0
From: Jaqcksonville
IMO: You've choosen the difficult way of conversion.
1. To make the conversion plate to fit A4LD is not so easy, TC will not fit manual tranny flightweel and you will have additional pain (
2. OD and TC Clutch are electronically controlled in A4LD, how will you controll them?
3. You are going to use FIP cabel position to get engine load, becouse you cant use vac. modulator with diesel. Belive me shift points will not be optimal.
4. Mechanical pump is not so accurate as EDC and ypu will have fixed injection timing, not variable as with EDC. Why not to use VW EDC with computer? You will loose 20-25% of HP and MPG.
Why not to find RWD powertrain? Engine and Tranny? There are small Mercedes, Cummins and Perkins engines (i do not say about duratorq of EU ramger) that fit Aero easily. Well, CRD Cummins B series with Allison tranny will be the best but the expensive solution. May be there is a reason to get 5 ore 6st manual tranny... More perfomance, more MPG!
1. To make the conversion plate to fit A4LD is not so easy, TC will not fit manual tranny flightweel and you will have additional pain (
2. OD and TC Clutch are electronically controlled in A4LD, how will you controll them?
3. You are going to use FIP cabel position to get engine load, becouse you cant use vac. modulator with diesel. Belive me shift points will not be optimal.
4. Mechanical pump is not so accurate as EDC and ypu will have fixed injection timing, not variable as with EDC. Why not to use VW EDC with computer? You will loose 20-25% of HP and MPG.
Why not to find RWD powertrain? Engine and Tranny? There are small Mercedes, Cummins and Perkins engines (i do not say about duratorq of EU ramger) that fit Aero easily. Well, CRD Cummins B series with Allison tranny will be the best but the expensive solution. May be there is a reason to get 5 ore 6st manual tranny... More perfomance, more MPG!
2. The a4ld would be an option however as you say vac modulator and tc lockup are a hassle.
3.The early Ford AOD trans, Zf4hp 22 are probably easier to adapt regarding trans controls. Line pressure readings will determine Throttle valve position regarding shifting and kickdown.
4. Agreed electronic injection pump control is the way to go. The VW ecu I have is a 60 pin ecu. The harness has a lot of extra feeds to lights and is drive by wire and bulky. The non electric needs one wire for engine control. Pump advance rate can be changed internally in the pump.
5. I have a sprinter engine. It is long and tall and to me more difficult to install and so much bigger. The other engines 4Bdt and isuzu engines are heavy truck motors
Thread Starter
|
Post Fiend
Joined: Oct 2005
Posts: 5,242
Likes: 0
From: Kiev, Ukraine
1. As the vw flexplate and flywheel have no ring gear teeth attatched the flywheel or flexplate from the donor vehicle engine which the trans and torque converter is coming from needs to be used. The flywheel and torque converter wont be an issue.
2. The a4ld would be an option however as you say vac modulator and tc lockup are a hassle.
3.The early Ford AOD trans, Zf4hp 22 are probably easier to adapt regarding trans controls. Line pressure readings will determine Throttle valve position regarding shifting and kickdown.
4. Agreed electronic injection pump control is the way to go. The VW ecu I have is a 60 pin ecu. The harness has a lot of extra feeds to lights and is drive by wire and bulky. The non electric needs one wire for engine control. Pump advance rate can be changed internally in the pump.
5. I have a sprinter engine. It is long and tall and to me more difficult to install and so much bigger. The other engines 4Bdt and isuzu engines are heavy truck motors
2. The a4ld would be an option however as you say vac modulator and tc lockup are a hassle.
3.The early Ford AOD trans, Zf4hp 22 are probably easier to adapt regarding trans controls. Line pressure readings will determine Throttle valve position regarding shifting and kickdown.
4. Agreed electronic injection pump control is the way to go. The VW ecu I have is a 60 pin ecu. The harness has a lot of extra feeds to lights and is drive by wire and bulky. The non electric needs one wire for engine control. Pump advance rate can be changed internally in the pump.
5. I have a sprinter engine. It is long and tall and to me more difficult to install and so much bigger. The other engines 4Bdt and isuzu engines are heavy truck motors
Thread Starter
|
Post Fiend
Joined: Oct 2005
Posts: 5,242
Likes: 0
From: Kiev, Ukraine
The easiest way - get old transit diesel engine and tranny from EU ore UK. 2.4D powertrain fits aero dog house EASILY!!! Just weld brakets on x-member and that's all!
ouh, DS must be 2" longer, but this is not problem!
ouh, DS must be 2" longer, but this is not problem!
Postmaster
Joined: Oct 2009
Posts: 3,432
Likes: 7
Pablo, that would be great if we could get this engine. Perhaps you don't realize just how few diesel options we have to work with here in the US. Diesels have been popular in Europe for some time, but here int eh US, we have the Sprinter, a few VWs, a few BMWs, and some 80's era Mercedes cars. There are a couple of others, but most of these are either rare or difficult to acquire cheaply. The engine in the Transit is completely out of reach. We can't just import them either, we have to deal with import laws on vehicles, and those that have not been approved for imports are extremely difficult to get.
Thread Starter
|
Post Fiend
Joined: Oct 2005
Posts: 5,242
Likes: 0
From: Kiev, Ukraine
Well, but there are many small diesel engines that fit aero used on Fork-Trucks (Perkins, Mitsubishi, Isudzu, Cummins)... For example there is small Hyster truck on my work with small 3L Perkins engine, this truck was built in Oregon. There are small Cummins engines...
Ouh, semi refrigerator may have up to 150 HP (100 is enought) diesel engines that drive compressors. My friend got ThermoKing 3 cyl engine for his old moskvitch, slow a bit, but 5l/100 KM!
Ouh, semi refrigerator may have up to 150 HP (100 is enought) diesel engines that drive compressors. My friend got ThermoKing 3 cyl engine for his old moskvitch, slow a bit, but 5l/100 KM!