TDI into '78 Bus Build Thread

[markd89]

[vwwestyman]

I got the head off today without any real drama.

I was pleased to see that the hash marks in cylinders 2 and 3 are clearly visible, and no obvious damage to the block or pistons.

Also I cleaned up the rear cushion. In all the disasters, I had tried to open the cap to help the system bleed after having added coolant and driven a very short distance. I had driven such a short distance, I didn't think it would have pressurized, but it sure did! When I tried to open the cap, a giant geyser came flying out, shooting straight up into the bus, and hitting the headbanger cabinet, making a huge mess. So the cushion needed washed.

Here's how I made sure it was rinsed well. I figured it was somewhat clever.

Anyway, here's a shot of the block, and old head before I stripped it.

And this is a very beautiful picture, indeed!

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Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[vwwestyman]

I did get the low coolant level blinky light to work again. (I guess I'll have to verify that it doesn't blink when hooked up to a full reservoir later.)

But it was blinking like it seemed like it should with the reservoir unhooked.

I think I somehow messed up the control unit (looks much like a relay).

This is the basic wiring diagram I had used to hook it up initially. I couldn't remember if I had the wire from the relay going to the positive or negative side of the LED with the other side hooked to the constant.

Turns out the "relay" does provide the ground for the LED and the positive side of the LED should be hooked up so that it has constant power.

I wish I could hook up a buzzer or something, but it isn't truly a relay and I killed one by trying that one time before. Maybe it could also trigger a true relay, which could control the noise maker.
_________________
Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[richparker]

Dropping the duckets and making it happen, kuttos!
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’71 Westy build
Adventure thread
’65 Deluxe Build
’63 Deluxe Build

[vwwestyman]

Thanks! And yup, getting ready to head back out there. I started with a little bit of a lazy morning browsing The Samba and then taking the dog for a walk. Had to get that in before the fireworks start back up, because he'll refuse to go out until after that nonsense ends late in the evening.

Finishing breakfast and heading back out. Though I already started a little work of moving some bits over to the new head while it was cooking.

The seat foam didn't dry as much as I'd hoped it would, and rain is predicted off and on through today and tomorrow, so I moved it into the shed last night, and turned on a heater this morning hoping to evaporate some of that water out.
_________________
Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[vwwestyman]

Now this is a thing of beauty!

I believe it is ready to set on the block. I'm always a little nervous at this part, but as I told my girl, I think that is a little bit healthy! Being a little nervous helps keep me from getting complacent.

I did note that with both camshafts set at TDC, they both have two valves partially open. But on the old head, one valve is open a little more than the other, and more than either of the open valves on the new head.

I don't know for sure if that could be indicative of an impending problem, but possibly it is turning out that the whole thing happening when it did can be a positive in relation to my upcoming trip! Hard to say, trying to be optimistic.
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Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[vwwestyman]

It runs it runs it runs!!!

I started it up and let it run for probably close to 2 hours as I checked over things, looking for leaks and such. I probably wouldn't have let it run so long, but I was trying to set the turn-on temp of my fan controller.

The low-coolant blinky LED works, IE it doesn't blink when plugged in, and does blink when the harness is unplugged at the tank (simulating a low-coolant condition). There is a minor issue in that it won't reset unless I remove and reinstall the relay. I believe this is because I have the control unit connected to an always hot fuse instead of a key-on circuit.

That is very minor for now, though.

Also, I finally fixed the engine lid prop! I'm silly excited about that! The plastic block broke years ago, so I just took the spring-rod off and used a bungee cord on the upper hatch arm to hold it up.

I finally got a new block from Bus Depot a few days ago, but couldn't find the spring-rod that night. Found it tonight, under an old turbo! ha ha

Its the little things.

Also while letting it sit there, it was raining and the window fogged up. I noticed something on the windshield.

My good friend and I like to take our kids camping in the Bus every once in a while. His 7 year old sleeps on the front cot.

I noticed Zach's name written in the fog on the windshield. Aww

_________________
Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[Tcash]

[skills@eurocarsplus]

[captincanuck]

[vwwestyman]

You know, it actually is a URO part. I ordered it from Carquest, which for the most part usually sells me the good quality brands. I did question URO when it came (I agree, the name alone makes it suspicious!), but it was the one I had on hand and available. Glad to hear that there was reason to be suspicious of it, or to have the confirmation.

I will order the good quality stuff and swap it out soon. For the moment, that one is better than the one that had a small crack somewhere and was weeping coolant.

Now I need to figure out what I did wrong with my windshield wipers!

I freshened them up per Colin's instructions, but they are binding somehow. I didn't think to test them before installing. Now when I turn them on, it draws a bunch of power trying to move and then the fuse pops. I could hear the alternator working harder when I tried to switch them on last night.
_________________
Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[vwwestyman]

So the Bus did great on the trip, covering 693 miles. No problems at all.

I had a really good time with the guys caving in Oklahoma at Alabaster Caverns State Park. It was certainly something I haven't done before.

With the smaller scoop, the engine got a touch hot while driving down but the ambient temps were 105 outside that day, so I am more or less satisfied that the engine temps were up to about 205 but dropped when I slowed down just a little.

In ambient temps closer to 95, the engine ran around 195ish. So, again, just about 100 over ambient all around. I think this is pretty acceptable all around, though I may still switch back to the larger scoop.

Here are a few pics from the trip:

Stopped in Medicine Lodge Kansas. Just behind the building is Carrie Nation's house (she is somewhat famous for chopping down bars with an ax).

We cooked the first meals on the exhaust system. Hamburger, potatoes, carrots, onions in foil packets. I guess diesel exhaust doesn't get quite as hot as T4 exhaust! Mine wasn't quite done... But still tasted pretty good!

On the way there, we decided to explore this abandoned bridge near Freedom, Oklahoma. There were no signs on this end of the bridge.

But this is what we found on the other end!

It's important to take a shower every day! But the park charged $1.50 for 3 minutes. So we built our own.

After the caving portion of the trip, I decided to head to Cheney State Park in Kansas as I worked my way home. Here is where I stayed last night.

This is why I wanted to do the conversion! Cruise was set when the pic was taken.

_________________
Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[notchboy]

shit right here

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[Stuartzickefoose]

Nailed it
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Stuart Zickefoose

2011 Jetta Sportwagen TDi 6 speed manual

206-841-7324
[email protected]

[vwwestyman]

The gauges are EGT measured before the turbo, Coolant, and RPM.

The red light is what blinks if I lose coolant, the green one turns on when the fan is on as an FYI.

The coolant gauge isn't totally accurate as far as what it is actually saying. However, it is consistent as far as where the needle is for a given temperature. So, if the engine is at 188, the needle will be about a needle-width to the left of the 180 mark. If the needle is to the right of the 180 mark but still touching it, that is just over 200 degrees. So I figure as long as the needle never gets to the point that the needle isn't touching the 180 mark to the right, then it is good to go. If I blacked out the numbers and regarded the top middle number as the high point of normal, then I could say it was completely "accurate."

The speedometer, however, is right on. It was always actually reading a little high with the factory tires. With the larger tires, it reads just about perfect.
_________________
Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[secretsubmariner]

Excellent, Dave! Damn, that bus has come a long way. it's awesome to see you enjoying how you intended after all that hard work. It gives me hope
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-Tony
ᏣᎳᎩᎯ ᎠᏰᎵ
1978 Champagne Edition Bus FI
1970 Auto Fastback FI

[vwwestyman]

My average fuel economy calculates out to 26.06 MPGs.

The weird thing was individual tanks seemed to vary somewhat wildly. IE, I had a couple tanks that were close to 30 MPG, and a couple close to 20, and one 25. I'm not completely sure of the explanation for this.

It was very windy for most of the time driving. Looking at the fuel records and where I stopped each time in relation to the MPGs, it almost seems that I was possibly most affected by side winds vs head or tail winds.

During the times in the side winds, I was not going as fast (60-65 because I was becoming uncomfortable with the heat, this kept it in check), so potentially the RPMS were a little low vs the power band and that was a contributing factor.

Or since they were different fuel stations each time, it could simply have been a matter of some having crappy old diesel fuel and some having good fuel.

The other piece is that the fuel gauge decided to stop working, so I was filling up a little earlier than I needed to otherwise, just to make sure I would not run out.

But the best part is the Bus was always able to maintain my requested speed, no matter which way the wind was blowing or whether or not there was a hill!
_________________
Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[vwwestyman]

[markd89]

The bus looks sweet!

Your EGT looks nice. 950*F at 80 MPH is better than I see. I've heard lots of opinions on safe EGT, personally I try not to go about 1050 on a sustained basis. That's about what I would see going 80 on flat or 70-something up a medium hill. Usually I'm going low 70's and not trying to set bus speed records
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78 TDI Sunroof Bus
Los Angeles

[vwwestyman]