TDI conversion parts/suppliers list, please add

[Bman]

[Zeitgeist 13]

You can boost a tdi way beyond those "chipped" output figures*, so just set a performance goal and a budget, and then right-size your install to suit. To my mind the tdi and 1.8t are by far the most appealing swaps on the market today.


*the torque figures are the ones to watch
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[MarkWard]

Last time on the dyno with everything stock we measured about 100 hp and about 150 foot pounds of torque at the wheels. I have not been back on the dyno since installing the EGR delete pipe and the Sprint Bozio 520 nozzles. Ours is a 1.9 ALH TDI from a 98 Beetle. You will need to plan on some regearing of the trans if you intend to do sustained hwy driving. Not because the engine can't take it, but the economy goes down the toilet. Taller tires alone are not enough. Diesels are not for everyone, and it would take many fillups to recoup the cost of a completed diesel conversion with this type of engine. Regards.
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[Hatterasker]

Just posted re same before seeing your thread

Is a TDI worth the endeavor to put in my '86 Westy?

How would I know that the TDI motor is worth a damn?

Thank you very much.

Matt

[MarkWard]

[Hatterasker]

Thank you, rsxsr.

I will do some sleuthing about the site to find out more.

[AndyBees]

[tclark]

I just wanted to clarify the fly wheel, pressure plate, clutch disk,transmission input shaft, starter options
(I just did a clutch job & I bought my tdi mostly converted & assumed an ahu 228mm fly wheel it was not)

Option 1
DV Flywheel, dv 215mm pressure plate, & dv 215mm clutch disk, vanagon transmission input shaft
-no modification to dv bell housing, no clearance issue of dv starter
-will slip under load going up a hill in 3/4th
-uses standard vanagon transmission input shaft
-some clutch chatter at idle, revs up quickly, skill req'd for hill starts
-RnR oil pan w/o tranny removal, allows access rear oil pan bolts

Option 2
Lighten 228mm 14-16lbs Flywheel, 228mm G60 pressure plate, & Vanagon 228mm clutch disk, vanagon transmission input shaft
-modification to dv bell housing, no clearance issue of dv starter
-uses dv dust shield and dust plate
-may/may not slip under load going up a hill in 3/4th
-uses standard vanagon transmission input shaft
-some clutch chatter at idle, revs up quickly, skill req'd for hill starts
-RnR oil pan w/o tranny removal, allows access rear oil pan bolts

Option 3
Lighten 228mm 14-16lbs Flywheel, 228mm G60 pressure plate, & TDI/Vr6 228mm clutch disk, HA/Brickwerks tdi / modified vanagon inut shaft
-uses dv dust shield
-modification to dv bell housing, no clearance issue of dv starter
-will not slip under load going up a hill in 3/4th
-modified transmission input shaft allows real tdi clutch disk
-some clutch chatter at idle, revs up quickly, skill req'd for hill starts
-RnR oil pan w/o tranny removal, allows access rear oil pan bolts

Option 4
Std 228mm 22lbs Flywheel, 228mm G60 pressure plate, & Vanagon 228mm clutch disk
-modified TDI dust shield, custom dust plate
-modification to dv bell housing, clearance issue of dv starter
-will probably not slip under load going up a hill in 3/4th
-factory clutch chatter at idle,
-RnR oil pan req. tranny removal, NO allows access rear oil pan bolts

Option 5- generally assumed to be the most robust option
Std 228mm 22lbs Flywheel, 228mm G60 pressure plate, & & TDI/Vr6 228mm clutch disk, HA/brickwerks tdi / modified vanagon input shaft
-modified TDI dust shield, custom dust plate
-modification to dv bell housing, clearance issue of dv starter
-will not slip under load going up a hill in 3/4th
-factory std clutch chatter at idle,
-RnR oil pan req. tranny removal, NO access rear oil pan bolts

Lightened 14-16lbs Flywheel
-you can also turn the fw down at the local machine shop
& should also send the fw,pp & clutch out for balancing
ECS http://www.ecstuning.com/Search/ES2597295/ES2597295/
Eurospec http://www.mjmautohaus.com/catalog/product_info.php?products_id=1126
AutoTech http://www.autotech.com/product/lightweight-flywheels/10-105-100K.html?fromcat=
Sachs http://shopping.boraparts.com/product_info.php?products_id=119

Input shaft
http://www.brickwerks.co.uk/index.php/t3-parts/t3-...3-tdi.html
http://www.ha-projekt.de/index.php?route=product/product&product_id=61

Modified AHU Dust Plate
http://www.tdi-umbau.com/getriebe-t3/abdeckblech-t3-zum-schwungrad.html

Then with any of these any of these options you can get a starter adapter
from Brickwwerks to mount a real TDI starter
Starter Plate
http://switchamotor.blogspot.ca/2011/07/tdi-starter-for-t25vanagon-adapter.html
http://www.brickwerks.co.uk/index.php/t3-parts/t3-...sions.html
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89 Westy with TDI AHU 1.9 manual lots of mods
85 GL 1.9, auto (for sold)

[MarkWard]

I am running a stock vanagon diesel 1.6 NA flywheel and clutch on my ALH TDI. 25000 miles and no indication the stock diesel clutch is "not" up to the task. Using a stock diesel vanagon starter on a diesel bellhousing.
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[tclark]

[MarkWard]

Do I live near the mountains? No. I am in Florida, but I have taken the van across this country many times. I spent time crossing the Sierra Nevadas, the Rockies, the Appalachian mountains, the Adernondaks, and the Green Mountains of VT. Our van does very little driving in Florida, only to come and go.

Perhaps I am easy on the clutch. I for sure don't drive it like I stole it. When it starts to slip, I will look into my other options. I don't recall the company, but we used to have heavy duty pressure plates made for reasonable amounts for our VW race cars that had much more clamping force, but fit the stock flywheel.

On the race cars we found that smaller diameter discs actually clamped better than larger diameter discs with the same pressure plate and actually shifted better because they had less rotational mass.
I don't know what the disc diameter is, when I did the conversion, I just swapped the existing flywheel, clutch and disc from the 1.6 that was in the Van.
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[TDI-Driver]

Dwight at www.HansAutoParts.com said that he's been building M-TDI Pumps for AHU/1Z and ALH Engines for 5 years. They run the pumps on a TDI engine prior to shipping them. They can build pumps with 10mm rotors or larger rotors to add more power. Larger nozzles in the injectors can also help flow more fuel.

[hans j]

[westyventures]

Just because a pump makes an engine 'run' doesn't necessarily mean it makes any power.

[zeohsix]

[BavarianWrench]

I have a JX 1600 turbo in a stock 87 Syncro. Do I need an adapter to install a late model TDI starter? What is the best set up to go with?

[syncroserge]

Yes you need an adapter. For a wbx bellhousing Karl (WesytVentures) has the adapter.
For a diesel bellhousing I just installed this one:
http://www.ebay.de/itm/VW-Bus-T3-TDI-Umbau-Anlasse...19ed3b55f2
with a fresh Bosch SR0408X the difference is impressive.

[steelvisions]

HELP! I am trying to install my 2005 2.0 TDI into a Baja Bug. I am being told by everyone that no one can reprogram the ECU to flash out all the limp mode demons. Can anyone here tell me what I need to do? I would greatly appreciate any help anyone is willing to offer. THANK YOU!

[AndyBees]

The answer to your question is over in the TDI Club where you posted the same question.

Jimbote gave some pretty good advice there in post #468.

http://forums.tdiclub.com/showthread.php?t=293577&page=32
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'84 Vanagon Tin-top, ALH TDI. 1989 Tin-top
1983 Air-cool, 225k miles, 180k miles mine. Seven trips to Alaska from 1986 thru 2003.

[rotaecho]

So, I've been looking at the photos between an AHU oil-pump and the DV oil-pump.

Someone was saying the DV oil-pump is better since it's designed for the 50 degree angle, but it looks pretty much the same from my photo comparisons.

I plan on using a windage tray too

Advice here of which is best to go with?

Thanks!