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  View original topic: AHU conversion prelimary questions ...vette this build ...
tclark Fri Apr 23, 2010 8:53 am

I want to do a m-TDI into an automatic with AHU Mk3 1.9 jetta97-99
Kep adapter/Flex plate, Cdn TDI motor, & m-IP
OK I think i have it mostly straight from this here
http://www.thesamba.com/vw/forum/viewtopic.php?t=402326
r39o/mightyart ->THAT SHOULD BE A under the Engine section here
http://www.thesamba.com/vw/forum/viewtopic.php?t=151300
with subtext (Parts for Diesel Conversion)


But kinda confused about what
- make an existing power steering still work do you need brackets , pulley a different pump ??
- alternator setup do you need brackets , pulley a different alternator

than what is on the tdi ?

fairweather Fri Apr 23, 2010 9:08 am

Use the TDI PS pump and stock vanagon lines.

Use the stock TDI alternator, only mod might be a clutched pulley which makes a significant difference in smoothness.

tclark wrote:


But kinda confused about what
- make an existing power steering still work do you need brackets , pulley a different pump ??
- alternator setup do you need brackets , pulley a different alternator

than what is on the tdi ?

tclark Fri Apr 23, 2010 7:01 pm

So can I just get a reality check on what I think I know :)
& kick hole in this parts build & what did I forget : :oops:

1) TDI Diesel 1.9 AHU 97-99 Mk3 Jetta/Golf ID by the screw on oil filter
-Injector pump
-Water pump
-Intake and exhaust manifolds
-Turbo charger with flange and down pipes
-Catalytic converter
-Inter cooler with all piping sensors and rubber pieces
-Alternator with cable that goes to starter
-Power steering pump, including high pressure fittings to the top of the PS -pump and a small section of the piping
-All belts and pulleys for the belt driven accessories
-Coolant bottle with all pipes between the water pump and EGR cooler
-Diesel fuel filter with bracket and pipes between engine and filter
and 10 cm of pipe on the non-engine side of the filter

$1000 Cdn http://car-part.com

2) Diesel Van(DV) donor parts
$500 DV 83+
-Pick up tube for oil pump,
-Oil filler tube, & the brake line fitting to allow lic plate ds access
-Oil pan,w/bung fitted on oil pan for turbo return lines
-Oil return line
-Engine carrier bars with the rubber isolators and
-Engine mount brackets.

3) Special left side motor mnt,
$XXX
OR
$ 750 flip turbo use std DV motor mounts
http://www.thesamba.com/vw/classifieds/detail.php?id=919197

4) m-injector
$ 1400 - $1600
Karl http://www.westyventures.com/parts.html
-all new good to go
Giles http://www.performancediesel.ca
-take 2 IP cores 1 from the TDI & 1 from AAZ + Full AAA coverage :)
OR this Guy famous phil l @ brickyard :roll: :roll:
http://www.brick-yard.co.uk/forum/mtdi-pumps-coming-very-soon_topic51175.html

5) TDI starter motor BOSCH REMAN #SR0407X or wps 2KW model
$ 70-$200
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=290223360012

6) TDI starter adapter
$ 70 http://www.westyventures.com/parts.html

7) new silicone hose kit from grease works
$ 400
http://www.greaseworks.com/store/product_info.php?cPath=24_66&products_id=535

8 ) kep #3600 adapter, flex plate(a spacer )
$ 460

9) 3.73 R & P taller final
$1500
http://www.germantransaxle.com/catalog/volkswagen/vanagon/final-drive-for-automatic-1/
you want drive want 70 mph = 3000 rpm TDI

10) Exhaust I guess this a custom build
XXX

hmm $6410 NO labour & no rebuild just parts & XXX for exhaust
Now with this build sheet is this all mechanical & NO fabrication work ???

westyventures Fri Apr 23, 2010 7:32 pm

tclark wrote:

3) m-injector take 2 IP cores 1 from the TDI & 1 from AAZ
$ 1600
Giles http://www.performancediesel.ca


You can go that route if you have super-extended AAA. :wink:
The AAZ pump has a small 17mm shaft and is prone to breakage when run with the TDI hi-pressure head. It also has insufficient throttle travel. The option is a brand-new Bosch m-TDI pump (with 20mm shaft) from me. $1000-1200 complete. I also test and set up my pumps on an actual AHU in my van, not on a machine. Downside? Ya gotta wait a few months to get one.

I can also supply the upper three hoses for about $150. The lower one is a custom build currently, to fit around the PS pump bracket.

?Waldo? Fri Apr 23, 2010 8:20 pm

Don't use the stock '83 diesel oil pump pickup tube. It has the integral oil control valve which is sized for a 30mm gear oil pump. The AHU will have the 36mm gears and so is not a good match. Get a complete euro TD oil pump. They are still available new, part # 068 115 105 BP. They are the 36mm pump with correct oil pressure control valve for the DV configuration. If you have A/C there is not any oil filler tube that will fit. If you have A/C and want a license plate filler it will be a custom job. I made one fairly easily from a WBX filler. If you do not have A/C but have power steering you can get a used later model 1.6TD oil filler tube that winds around the pump and it will fit.

You didn't comment on air filter, intake tubing, intercooler, glow plugs.

tclark Fri Apr 23, 2010 10:10 pm

Andrew A. Libby wrote: Get a complete euro TD 36mm oil pump. part # 068 115 105 BP. ...If you do not have A/C but have power steering you can get a used later model 1.6TD oil filler tube that winds around the pump and it will fit.
OK thxs for that heads up
$223
http://www.worldimpex.com/parts/genuine-part-oil-pump_43968.html
Andrew A. Libby wrote:
You didn't comment on air filter, intake tubing, intercooler, glow plugs.

dont know what I dont know ...so where or what do I track down for those parts ?

any any pro-cons of the left motor mount from GW vs standing the turbo on its end vs Quantum TD exhaust manifold & using a T3 turbo

and am I right with the above build I have no fabrication work just mechanical assembly ?

?Waldo? Sat Apr 24, 2010 12:03 am

http://www.greaseworks.com/store/product_info.php?cPath=24_66&products_id=510

That will save you a few dollars. They have the Meyle version of that pump for even less.

Your air filter and intercooler system is going to be custom. You'll want to research to see what you want to do in that regard.



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