How to Diesel Swap a Vanagon - 4x4 Camper Van Build 2.0L TDI 

Imagine an old man sitting in a cabin in the middle of north Idaho thinking he’s all alone and all of a sudden a diesel 4x4 vanagon and a 2 stroke snow scooter just zip by him out of nowhere😂 love the stuff you guys do keep it up!!!

Am I the only one who would love to see a diesel power wheels project. Love what you guys do. Keep it up

I've seen and done hundreds of German-Engine-Swaps but this is totally different and amazing. Love it. Greetings from Bavaria Germany

YES, I was waiting for you to finally do something with the Westy I’ve seen in the background of all your vids. I have a 2.2 Subaru swapped Tintop Vanagon and a Westy full camper so you’re all right in my book.

Instead of having a low vulnerable oil pan you might look into a drysump setup which trades the big deep pan for a thin scavenge plate. Great project btw, absolutely love the syncro!

Really want to see that tdi jet ski.

As a tdi owner, I can say you won't have any regrets. Love the content guys! Keep it up!

i love that this guy found his niche. he is definitely living his best life

TDI swap the world! Such an awesome build and crazy how fast it was all completed. Last summer I did my first engine swap and put a 1.9 PD130 engine into my Audi A4 Avant. This summer I upgraded to a GTB2060VKLR, and it's an absolute riot. Can't beat AWD manual TDIs!

Hats off to that man, the sheer craftsmanship and detail is out of this world, that’s so bad ass looks OEM plus

Man, the one dudes wardrobe was primarily made up of AvE tee-shirts, LOL! Looks like a sweet swap!

I have an alh TDI in my 86 westy. It really is the best thing I’ve done to the van. You cut the input shaft on the trans, the shaft has a taper from where the OG bearing sat to the splines. It was cause a slight vibration that you’d contribute to diesel swap and it will take years to do any damage but it will eventually take out the bearing and input shaft. Also had to put a new gas tank in the van as the diesel ended up dislodging all the spuz that stuck to the inside and clogged my fuel lines.

That departure angle though, gonna need a bash guard

That oil pan hanging low is looking like a big problem. Next is making a skid plate ? Sweet setup though great content.

These are some of the best vids on YT. These guys dont laser measure and spec torque. REAL LIFE wrenchers.

I did a swap for a customer a year ago and used his kit. amazing kit! Very very nice quality! You will be very happy with the swap!

11:51 pupper was like, you need a hand with that trans, nah you got it

Very cool swap. I have the AFN 1,9 TDI in my Syncro. Always remember and never forget, your Transmission was never build for that amount of torgue. Enjoy the more power and speed.

I am so excited about this project. I have driven about 10 different VW Caravelle models in South Africa and found the power lacking to pull a tow-behind RV. I have had a V6 ford engine put into some of them, but it overheated easily. This would be such an improvement on that! I wish you many happy miles with this great transplant.

So cool seeing some great quality vanagon content! I’ve been working on them a while now and this is my ultimate dream build. I’ve been filming my builds and progress too. Good work man!

Love this. I’m putting a 1.9 tdi in a 96 Land Rover Discovery. I’m converting it to a mechanical injection pump. I’m mating it to a BMW 325 xi manual trans, that will be mated to the Rover transfer case.

I don’t think you’ll regret it. Plenty of people put the older 1.9 TDI into those things and love it. I just got finished putting a 1.9 TDI in my Ranger and I’m loving it so far. Needs some attention in some areas, but’s a custom creation so it’s a journey, as I’m sure we all know.

Simply you guys are awsome. These are things me and my buddies get into doing lol not on your scale but same fun factor just never in a million years would of thought to record let alone think that people would want to watch. Keep it up guys the world can use positivity like this.

That shirt on 23:11 is so nostalgic! My dad had a 1991 VW Syncro, lifted it and put 18" rims, took that thing to Botswana and even towed a Toyota Hilux 80km through sand. Sitting inside and using the vacuum pump to enable the diff-lock was the best. He also replaced the engine 3 times from 99 to 2004 before selling it in 2005 because of overheating and blowing a piston through the block.

god damn them tracks are fire. Seeing it this great now is amazing. cant imagine what you'll do in the future

Dude, you have NO idea how much I desire your van. Carnal levels of want.

GHPC gives me so much motivation to live your best life. I keep looking at ID as a wonderful place to live and i could see Ethan around town.

This engine is my dream. I have wanted one for years. I have a beautiful 87 GL for over 20 years. She has blown the head gaskets twice over the years and now sits in my garage for the last 6 years. I follow BOXEER on Facebook and dream every day.

I'd recommend some under engine shielding. Can imagine the debris damage from rock deflection etc from being at the back. Couldn't tell what the stock had.

23:48 the younger fella hits his head on a tyre and leaves the scene keeping his cool. 😂

Really liked this. Great upgrade, must make a biiiig difference in this kind of van. Keep doing what you're doing, loving all of your work. 👍

I LOVE your van! When I was like 13 my friends mom had one 4wd with low gear and diff lock and we would sneak out and take up crazy logging roads in northern washington! It would go anywhere!

When you guys hit 1 mill I will be so proud. Right around the corner....

I have no idea how hard it would be to do, but a dry sump would be sweet. That way you have even better clearance and don’t have to worry too much about scraping a pan. You also could do a nice skid plate with the extra room too.

Hands down my favorite video from GHP yet!

I own a 1.9L TDI in my MK4 Jetta. Love these motors!!! Awesome what you do.

Seeing as how it was so unreliable, I got the engine drop on my VW splitty down to 13 minutes. 4 wires, 4rear panel bolts, 6 bumper bolts a fuel line and a cable. I would love a diesel conversion for it.

Anyone else notice the power wheels on the hoist in the back?

Love the way this thing sounds. All the turbo noise. Great video guy's.

I used 1.9 alh engine on oe TD 5 speed GB. Tilt 50 degree. No projection on the lid. Crankcase, I have fused TD into TDI crankcase. I loved your Audi engine mount bracket.:):) clean work.

Is that a garage build in feeling? Grind hard garage with bike lift and car lift, smooth floor and high roof? And maybe even a dry storage for the builds :o

I saw that Barbie jeep on the lift in the background... Nice touch!

at 12:33 he's talking about reinforcing the shaft/fork mech for the clutch so it doesn't fail. Yeah, mine failed on my '85--had no idea what it was, limped back to town, took it all apart. Easy fix when I saw it! good work.

I was wondering about that Vanagon for some time. And it's a Synchro! So jealous. Awesome rig with the TDI swap!!!

I met greg at a car cruise-in in MI a few years back. He had his blue/teal 4x4 Westphalia with the TDI conversion. This was, I think, shortly after his Pikes Peak run in the TDI Beetle race car. Very cool guy.

And a diesel powered Jet Ski..HELL YEAH

Oh yes I love this so much, quality content right here!!! Keep it up boys!

I used to be super hard core VW guy,over 30 different bugs busses square backs rat rod bug and had a 91 vanagon for a while.The 60 bus was the one that got away!Cool seeing that Kootenai county Idaho plate in Tennesee,as I grew up in Samuels Idaho,just north of Sandpoint.

Lol, Ethan looks like he haven't slept in ages. Love your videos guys.

it's about time you worked on the syncro! i have an 87 4wd that i'm putting an ALH in at 15 degrees.

This is my favorite swap you guys have done so far 😀 awesome

Wow! Never heard of this conversion before. Yay!!!! Looks awesome to say the least. Miss my Syncros!!! Miss my '89 Wolfsburg Carat too! Loved my 5spd '93 Eurovans too. But of course, there's nothing like the Syncro and NOT GETTING STUCK in the snow, muck, and ice up here in New England in the winter, or on the beach! Can't wait to win the lotto and bring back some early 2000 models from South Africa with ABS and Air bags! ha! Just two more years to go till the 25 year import mark. :))

Yeeeeew it’s Moab Time

Time for a TDI badge on the back !

That thing is a beast now. I enjoyed the long format full build.

Sweet set up guys lots of work in just 4 days I noticed the big smiles while you guys were driving Great video bro Fireman 🔥🔥🔥

Being from europe, it's so weird to see people get excited for TDI sound.

Next is you fabing and putting on the giant greasy skid plate to protect such a low slung oil pan... Right?

Keep it up guys! Your videos look great and the music is matched to the theme

I am totally amazed as too how many talented and highly skilled professionals there is in the states amazing just wow so superb and superior 👏🏆👍🥇

I love it, but it’s hanging pretty low. And those hoses looked to be laying close the CV boot on the right side.

isnt this the guy that brought the diesel bug to hoonigan that had like a porsche transmision n shit?

i have been waiting so long for this well done lads

Love this vid. I've watched it a couple of times. I'd love to see a follow up on how your Vanagon is doing, long term, after the swap.

I feel like she could really use a skid plate under that engine

i would be so worried about slamming that pan on a rock. please tell me you will lift in and put a guard on it LOL

YESS YESSS SO FREAKING PUMPED FOR THIS BUILD!!!!

BadA$$. Used to do these swaps at Fine-Tuning and Small Car up here in the PNW along with Subaru flat six swaps from the SVX or Impreza fours and VW 2.0s as well. Brought me back to see your build thanks!

Diesel 4 seat jet ski Ok you peaked my interest

How long will the stock gearbox hold up to that motor? I know when doing any engine swap on a bug they say yo use the van box but being the Van's heavier then the bug wouldn't it be a ticking time bomb so to speak?

Congratulations beautiful project and mechanic skills. My greetings for Snellville GA.

Super close to 1 million congrats guys! Super cool swap!

my dad put an 911 engine in one of those VW vans back in the day

Is that a Fun cup race car in the background? Didn’t realise they’d made it to the US.

Awesome to see people design and install modern reliable motors in a classic loved vehicle.

Looks nice. I have a syncrostien. (a 2wd van that I used a rusted out syncro for it's conversion.) I ended up converting it to a pop top as well. So it's truly a Frankenstein. The added kicker is I was one of the 1st guys to put a 2.4 ecotec motor in mine. Super awesome motor for the Vanagon, but I got the diesel bug and I've been thinking of doing a diesel swap just because.. you know lol That set up he makes looks super nice. I lived in the van for almost 2 years road tripping with that ecotec I dunno why I'd ever change it but the diesel is calling..

My boy Greg wearing Fjallraven! Represent.

5:48 I spot an AvE fan

I drive a 2011 tdi golf. I would LOVE to have a van like this. Incredibly versatile fun vehicle

Nicely done! Super cool!

Im trying to weigh out the pros and cons of this kit over a subie swap. My biggest concern with this is the loss of clearance in the rear. Not sure how you are supposed to use the bed anymore unless you hollow out the rear cushion.

1:34 Is that the next next next project!!?? (On the lift)

Wow that swap kit is amazing! I wish someone made a TDI swap kit like that for my Jeep XJ.

This was really sweet. You grinning the whole time was pretty fun watch. Simple looking project in 4 days.

When do we see a diesel power wheels build?:)

Now all you have to do is see if it survives whistlindiesel

Can't wait to follow that build

Great little project, looks like it worked quite well 👍

Just get bigger tires with more power to turn them easily.

Do they make one that would work in the older beetles?

Nice build man. Enjoy it.

I liked the Home Depot bucket under there with the "Let's Do This" showing

So much for the break in period as he mashes the pedal and black smoke rolls...

I thought I recognized greg from somewhere, he did all those cool subaru EE20 diesel swaps a while ago

nice clean build... I had a 2003 ALH TDI (108kW) put into my 1989 Westie in 2009 and it worked pretty well... one thing that was noticeable right away was the resonance noise from the engine just above 3100 rpm, which with the stock transmission was about 65-75 mph. I think that resonance is pretty universal for the TDI and VW went to great lengths to keep the engine speed down in the Jettas and Golfs. Another problem that turned up was due to the Wasserboxer low torque power train design, on one trip the bell housing cracked, and later the 4th gear blew up (but we made it home in 3rd!). I had a 5 speed transmission from Germany built with the gear ratio 4.11:2.33:1.48:1.03:0.74 and put larger tires on the car (6.82' circumference) which improved the milage to roughly 30 mpg and cruising on the highway at 75 mph (at about 24 mpg) running below the resonance. Eventually the fuel pump clogged, once again leaving me stranded. Probably should have changed the fuel tank (as recommended in an earlier comment). In that build the engine was raised higher to retain the high clearance of the original engine and even though it was two wheel drive it held its own in rough terrain. With time the Westie, which was supposed to get me to and from my adventures became the adventure... so I sold it to the mechanic that did the conversion... Good luck with yours! have fun... obviously I'm still in love with the idea as evidenced by viewing this episode.

Nice kit!

You guys need to do an electric motor conversion on something or build something around an electric motor. I feel like if you built a buggy from scratch with electric motor and all that it would be badass!

Getting famous off of comments day 175, so I can live the dream, live life to the fullest🤙🤙

You guys did an awesome job it looks sounds and runs nice! Shes a beast!!🤙

This is awesome! Also congrats on almost 1 million subs!