TDI conversion parts/suppliers list, please add

[AndyBees]

FWIW ...

Below are some pics showing where to remove material to mod the diesel starter to fit the G60 style flywheel and others.

Below, you can see the area where the starter nose will rub on the flywheel. In fact, if the starter is not modified, the engine will be locked when the starter is bolted up. The "added" TDC mark fro use on the diesel bell housing can be seen as well.

I later opted for the TDI Starter and adapter. The TDI starter required the use of a relay for the solenoid to operate properly.
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'84 Vanagon Tin-top, ALH TDI, two trips to Alaska, 2014 & 16. 1989 Tin-top unmolested.
1983 Air-cool, 225k miles, 180k miles mine, seven trips to Alaska from 1986 thru 2003. 1975 Bay hopeful.

[r.e.wing_fc3s]

i ended up deciding to clearance the starter after i could pretty clearly see where it was interfering. that and depressing the tabs on the pp make for a great setup. little if any increase in effort over stock. no chatter or vibration. glad to see thats what other folks have figured out as well.
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Reference Automotive: NW Washingtons Vanagon Specialist. (360)366-6965. referenceautomotive.com

[Christopher Schimke]

[westyventures]

The stock diesel starter will fit with the TDI flywheel, you just need to grind or file a small bit off the nose casting next to the bushing.

After thinking more about producing an adaptor, I decided that the demand wouldn't warrant the bother. I chatted briefly with Simon Baxter at Brickwerks and he said he would begin shipping some over for interested people. Easier that remaking the wheel, and good guys, good pricing.
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1990 Syncro 16" sunroof Reimo highroof conversion
1990 Westy Multivan 112i automatic
1992 LT31 Karmann Distance Wide 'La Tortuga'
2014 Touareg X TDI

[MarkWard]

This does not answer the specific question about a starter adapter, but when I upgraded my clutch, I used this thread as a reference. https://www.thesamba.com/vw/forum/viewtopic.php?t=...highlight=

I posted the clutch kit I used along with the outcome. I bent the pressure plate tabs in to maintain the balance. I clearanced the bell housing slightly using Andy Bee's info as a reference. I kissed the end of the starter housing with my grinder too per Christopher at T3. Rather than test fit the bellhousing, I just took a chance and bolted the transmission back up. No indication of any rubbing.

Stock diesel starter is working fine. Worse case, if the starter craps out on a trip, I will need to address the starter clearance again. I don't know if the Valeo flywheel I used is different from what you have. It is a TDI dual mass delete kit. mark

[rotaecho]

Karl @ WestyVentures was talking about starting some up a few months back, but not sure if he's started production of those yet. I know he started gasser adaptor production.

I had to source mine over the pond at BerndJager.

Call Peter @ Van-Cafe, and ask if it'd work on the DV bellhousing. He's really cool & responsive!

[r.e.wing_fc3s]

Anyone know if there is a source in the U.S. for the adapter for the diesel bellhousing to use a tdi starter? I cant get the 228mm tdi flywheel to work with the stock 1.6 starter and dont want to wait to order one from overseas. I see van-cafe sells some but they dont mention if they work with the diesel bellhousing.
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Reference Automotive: NW Washingtons Vanagon Specialist. (360)366-6965. referenceautomotive.com

[AndyBees]

[westyventures]

[nickgiles101]

Hello

I am trying to get the right answers, but seem to be getting mixed messages from different mechanics and parts suppliers. Here is the low-down:

We have an 82’ Westy with a 1.9L Golf engine, it is very slow and we would like to upgrade. Found a mechanic in Alaska (Accurate Auto) that said he can do the swap as long as we find him the car. He assures me that he can do it.

Now here is where things get interesting (keep in mind I am not mechanically inclined), AK guy says we need a conversion kit for the TDI. Okay fine I call Quality German Auto Parts as recommended by you all. German guy tells me we don’t need a conversion kit because it has already had an engine swap done. Is this true?

He also tells me AK guy will need to modify the left motor mount, install an intercooler (which I may already have, again not mechanically inclined), and maybe think about a second oil cooler since we plan on driving it down to the Lower 48 for an extruded road trip. German guy also tells me we might want the gearing changed in the tranny to get optimum gas mileage.

Does any of these make sense? Do you have clarity, wisdom, and knowledge to bestow upon me? Please and thank you!

[rotaecho]

I had BP on my build notes on the website. My brain had a major fart. I even found the 068115105BP one in the garage I purchased a few months back. It's been a hectic few weeks from my brothers death, so I'm still a bit scatter brained.

Thanks for putting the time to respond.

[westyventures]

BP is the correct number. Not the other.
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1990 Syncro 16" sunroof Reimo highroof conversion
1990 Westy Multivan 112i automatic
1992 LT31 Karmann Distance Wide 'La Tortuga'
2014 Touareg X TDI

[rotaecho]

Wow! Good information glad I caught this!

There's two P/N's I see for the DV oil-pump:

068115105BP

and

068115105BE

I see BP in stock in various locations, so am I correct to assume this is the proper DV oil-pump?

[westyventures]

[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!

[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, two trips to Alaska, 2014 & 16. 1989 Tin-top unmolested.
1983 Air-cool, 225k miles, 180k miles mine, seven trips to Alaska from 1986 thru 2003. 1975 Bay hopeful.

[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!

[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.

[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?

[zeohsix]