1.9TDI AFN and chargecooler install 16" syncro multivan

[Silentbay]

[lloydy]

Here you go
http://westfield-world.com/gtc.html
_________________
16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[Silentbay]

[lloydy]

I ended up taking off the HA projekt mounts as they stuck through the bottom of the bashplate (mine is the late much bigger bashplate) I went with the tried and tested Bernd Jager hydraulic mounts. Much more slimline and work much better with my syncro
a couple pics of the trial fit

They need to be welded on and lined up properly which was done by a friendly local syncronaut

Right hand side also uses a hydro mount

Bashplate and exhaust now all fitted

Glad to now have this all done Italy trip in a few weeks...
_________________
16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[lloydy]

Sorry for not updating this, but had a lot to do as you will see from the following posts
I got my van back on the 19th May, i was not happy....
Most of the story is on this thread, page 50 onwards http://forum.club8090.co.uk/viewtopic.php?f=4&t=78449&p=7762298#p7762298
It started with being told by the installer the engine lid no longer fits...
Its basically a photo diary of me putting the van right
Ah well, best to get started then.
Got on to correcting the engine lid
Cut and measured for the patch

Then fitted the brickwerks kit, nice little thing really, forgot to take a photo before fitting insulation pad

Only sits about 3mm proud, just need to replace the broken catch now
Then fitted the oil pressure sensor to the oil filter housing

And the temp sender to the back of the head

I've also changed the oil and fitted a sump plug.
So, as per the other thread, air inlet issues
i don't think this will promote good breathing
it actually almost completely blocked the filter inlet due to closeness to filler neck

so for now have removed the snorkel

also need to find a solution for the top end of snorkel, not particularly air tight

I think what i am going to have to do is move the battery 90 degrees, but this will foul the power steering pump. So battery will have to slide into the recess slightly. This will have to be done so the apollo can be straightened a bit, and give a bit more room for the run between the battery and rear light, as you can see, not quite enough space.
battery removed

from rear light

from above

Also need to replace this pipe as its mild steel
Also need to find a solution to the dipstick

As you can see, is just the standard AFN one, so measures thin air. Thanks to a tip, i'm using a coat hanger to measure oil level for now. As the dipstick was short i had filled with an additional 2 litres of oil before i clicked that maybe the dipstick was short Best coarse of action was to drain oil and start again with 4L of fresh oil. Found and changed the new addition of a bolt and sealant for a sump plug while i was there

I think the only sensible option open to me is to lengthen the dipstick ( i do have one coming from a breakers which might be long enough, but it looks to be slightly smaller around the part it seals) Maybe at some stage i'll be able to get a jx one put in.
Also not to sure what to do about the oil filler assembley, as mine has been left off, not easy filling through the rocker cover
While i'm trying to figure out what to do with the air inlet stuff, guess i can get on with cleaning the interior. In February it was pretty much top notch, what a difference 3 months out of my hands can do.......

so, i've been racking my mind, crawling under van, measuring here and there trying to work out a way of getting this air ducting to the apollo in a way that i can then straighten the apollo so i can attatch the snorkel. It all seems pretty labour intensive, and it seemed the only two options that would work are either move the battery tray further back towards the power steering reservoir or find some way of running the ducting low down and go under the battery. Both are tricky and come with their own problems..
So had a bit of a eureka! moment, why not use a shorter taller battery??? So i started searching, and i found this http://performancebatteries.co.uk/product/56069/ H 221mm W 170mm L 230mm
standard H 175mm W 175mm L 275mm

Now, the lip on the engine lid surround is 230mm +/-1mm So will be close to the engine lid. But i do have the fibreglass one, so no arcing probs, and i could remove the bleack sound deadening stuff around the battery area and stick a rubber mat there.
This battery will save me 45mm in the area i need, plus it is 5mm less wide so thats good too.
one of the other things i had to buy today was 10l of coolant as that wasnt added either
so, to put a smile on my face i fitted a couple bits i've had laying around.....

tdi

and my new battery turned up

So, deeper into the abyss we go..
as per other thread, on my way home from my weekend away the boost pipe to chargecooler kept popping off everytime i went near a motorway hill. Found this mainly to be because a bit of exhaust pipe was used as a joiner, with no swage on the ends. Being painted black did not help as the paint was coming off, aiding the silicone popping off.
you can just see it in this pic

offending part removed

I dropped the bashplate and fitted proper hoses and joiners. Not as pretty, but does the job right

a you can maybe see from one of the pics, the inside of the pipes were oily. So i thought, while the bashplate was off i'd look at the turbo. Oil was dripping from the air inlet, then noticed the oil return from the turbo

Hmm, seems to run uphill?

yep, another angle confirms it
and from the other side, you can see the oil return on the left rising up over the new engine bar before i drops back down to the turbo

Also noticed the original engine bar still in situ, but cut in half and the oil return up against it

Now call me crazy but in all my years as a plumber i alsways though liquids run downhill..
Also at this time, i find oil dripping from under gearbox, after a chat with the friendly gearbox builder, he points me in the direction of the breather on gearbox. Not even done up hand tight, so got that nipped up
Worth mentioning at this time, that my bashplate had the rubber flap on the rear to seal between bashplate and engine/gearbox. This was missing when i got my van back. Found it today though when i removed the bashplate, it had been broke off and shoved in inbetween bashplate and sump

Thought i'd check out the right hand side of the engine as well. Glad i did..
To start, this is what my right hand engine mount looks like

and from underneath

You can imagine i was slightly concerned when i could see some of the thread between the mount and block

this bolt just pulled out, seems to have stripped the thread in the block. You might be able to tell from the pic, that the part of the engine mount the bolt goes through is bent up, and also that it has a spacer/nut welded behind it, now the other bolt you can see from underneath

The mount on this side is not flush to the block, due to this the bolt does not screw down flat to the mount. As you can see, there is daylight under the head of the bolt. Now not being a structural engineer, i can only speak as a mechanical engineer. Firstly i'm a bit suspicious of the strength of 4mm sheet metal, bent or welded and used as a engine mount (it all seems to be made out of this). Then to compound that, have 8mm spacer one end and not the other so the mount does not sit flush, i would imagine this would cause extra stress which has raised itself by stripping the thread in the block and bending the engine mount. And just to top it all off, i found wedged under the engine mount, inc into the gap formed by stripped thread, a nice oily rag

so this was either put in and the mount tightened down, or the bolt on the mount had already stripped when the rag was put in

Looks like a purchase from HAprojekt is in order and then some jx engine rubber mounts
HA have posted the their engine mounts today, so looking good to get them early next week i have next week off work, so will hopefully get all this mount business sorted. Most annoying thing is having to drain the oil again due to needing to fit a different oil return pipe so it drains the right way saying that, need to remove the oil filter and maybe the housing to get at the engine mount bolts anyway.
The next job to get on with, will be to reconnect all auxiliary stuff like fans and gauges. As there was only "time" to leave it like this

Cables all live by the way......
Employed some child labour this morning and got my overhead blowers wired back up

So got the engine strapped up and removed the RH engine mount and hydraulic mount
People seem interested in them, so here's a few pics
block to mount bolts

top of hydraulic mount where it connects to metal engine mount (thought the nut would be nylock?)

part of mount that bolts to engine bar

Few more shots of the same section

section between hydro mount and block

spacer to seperate the two

together

all together

Had a go at sorting the battery problem, with it fouling the air ducting. I bought a smaller but taller battery, the CCA is more than the standard battery it replaced.
First had to remove a couple lugs from the battery tray, Mr MM might spot a bit of rust there that he can mentally note for another time

battery fitted in with aftermarket clamp, had to replace the negative from battery to below alternator as it wasn't long enough, the positives all were fine for length

and a view of the extra space created, cant see any problems straightening the apollo now, and then just replacing the sections of exhaust pipe that have been used...

Sooooooo, feck it.... power steering pulley has been rubbing on engine carrier bar
can just about make it out in the pics, it made about a 1-2mm 'cut' in the bar

you can see where its rubbed on one edge of pulley and not the other

Guess i'll have to fit the HA mounts and see what it looks like. But i'm not liking the look of it, will have to find someone to reshape the bar as the chunk taken out of it goes about 99% through it, then a bit added to the back. Will be one of those things your constantly checking. Feck!
Been out doing stuff this afternoon/evening doing stuff, then on the way home got the call from the mother in law that the engine mounts had arrived! So picked them up on the way home..
They are VERY sturdy! No bolts included though for bolting them to the block, so will have to work out the correct length. I've emailed HA to see if they know the bolt lengths and whether they have install instructions. The metal thickness is about 3X the thickness of the ones coming off, so should have no problems from them

think i might have put the plate the jx mount bolts to on back to front here

Made a start on the HA mounts today. Got the installers mounts off, don't want to keep on pointing stuff out. But 2 of the bolts that hold the mount to the block were in by 3-4 threads..
This bit is missing from my engine bars, so if anyone can help..

removed the exhaust and pipe, My late set up has been removed and replaced with an early set up, (late set up was on when i last saw the van) I want to go back to the late set up, but i am missing a lot of the bracketry. It looks as though the HA mount is designed for the late set up going by the orientation of the bolt holes and exhaust rubber mounts already fitted

other side

I'm hoping i am just missing this bracket from the RH side and then a late exhaust will bolt up to the HA mount...fingers crossed
I hope this is the mount http://www.vw-t3-bus-shop.de/motor/schalldaempfera...cht-2.html
A few more shots of the new mount bolted loosely up, i need to get the right length and grade of set screw to fit them proper and find that missing bit from my engine bar, and helicoil the block,and buy the correct exhaust and pipe, and buy the HA flexi extender for turbo to exhaust, and find a jx turbo steady mount, and...well you get the picture...

Just had a crawl under the van to see how the new mounts fit, and thought, why have i got all these threaded holes running along here? Then it clicked! My exhaust heat shield has gone missing too
Well i've spoke to HA, the late exhaust system bolts straight on to their mounts, the early one needs a bracket made up. I'm picking up a late exhaust and pipe today/tomorrow from GSF, and i have ordered a exhaust adapter from HA which is basically a flexi adapter that joins the AFN turbo to the JX exhaust pipe. This means standard exhaust parts are used.
i've then had to order the brackets from bernd jager for the late exhaust I'm now waiting for shipping costs from him, as his site doesn't automatically add that on.
Bolts for the engine mounts turned up today Had to order online as everywhere local wanted me to buy a box

Have just fitted the right hand side. i'm posting all these pics, not just to show what i am doing, but so if people google search for info hopefully this thread will pop up and they will be able to see pics of this stuff fitted, as i could not find any! Also might give someone more of a clue if they are looking at getting a tdi conversion.
Right hand HA projekt mount, 3 X M10 bolts, 10.9. one at 25mm long, one at 35mm long and one at 50mm long

good thing with getting this side done, is i can now get the oil filter and housing back on, Oh yes, need to drain the oil too, to swap over the oil return line
Will hopefully get the left hand side on tomorrow
Got on with the left hand side today
HA projekt left hand side. 3X M8-25mm 10.9
1X M8-30mm 10.9

As you can see from the last pic, not perfect alignment, but there is no adjustments. new oil return fitted, now with a much better fall

Now to the slightly annoying bits.. The little galv'd part i asked about previously, well i've found a brand new one (brickwerks) so can't finish off that engine bar until that arrives. Neil kindly lent me his spare one, but it would have cost more to get the threads un galv'd than a new one costs
Drained the engine oil to do the oil return, so thought i'd refit the oil/coolant cooler and fit new filter. I then realised new RH mount mount fouls the oil cooler Spoke to HA and find out you have to use a filter bracket fitted to some golf tdi's (1Z,AHU,AFN) part number 028115417 which makes the filter come out at a 45 degree angle. The one fitted to mine had the same part number but with a A at the end, a check on vagcat shows it to be from a petrol golf?? Anyway preloved bracket on its way to me.

Then looking at the new LH mount, i thought blimey thats going to be close to the bashplate. So did a little trial fit.......Yep it hits it
Marked up where it needs adjusting, its only by mm, but best to take 20mm off or so

View from the other side, need to twist the oil return a little

I imagine this issue with it touching could well be a late bashplate issue?
Also picked up a new late exhaust and downpipe today, just waiting for the brackets from Jager and flexi adapter from HA
Did a couple of things i actually wanted to do to the van this morning. just as a treat like, for fathers day
Brackets for Fiamma

And fitted the scangauge, want to run the cable a bit better

got a set of these coming as a present http://www.ebay.co.uk/itm/320718220081?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649
Didn't arrive in time though
While the kids watched last action hero i snuck out and had a play with the snorkel and Apollo...
Removed the Apollo, and fitted it in a straight line, also moved the MAF right on to the Apollo as i didn't see the point of it being further down the ducting making more joints.

Its now nicely fitted with the snorkel and no flattened ducting

No more crushed exhaust pipe

Started the air ducting today, need one more 45 and a joiner as i have had to go around a powersteering pipe Delivering before 12 tomorrow so not too bad. So far...

new strengthening bracket for engine bars arrived (brickwerks) so got that fitted, No more jacks or strapping holding the engine up

Also got the vss sensor fitted to the back of speedo (RJES) and wired it up to the loom (thanks to syncroandy for answering phone to help a numpty work out cable colours ) Now just to get a cruise control stalk......
No the engine is self supported, had a look at the previous problem of powersteering pulley rubbing the engine bar. Clears nicely now, so the engine must have dropped when the engine bar bent/stripped the thread. So good news there.

As far as i am aware, all of the issues i had with the van are fixed, things are looking up. Air inlet will be finished today. Then just have to fit the oil/coolant cooler bracket when it arrives and fill up with water Also need to butcher the bashplate a bit too. So barring unforseen problems, hopefully end of the week i'll be driving the van around.
Silicone hoses eventually arrived today, so nipped out and put those on

All the hoses now complete from snorkel to inlet manifold
Just waiting for the final few things to arrive now, quite frustrating really as it could be running now
1, exhaust brackets
2, exhaust flexi
3, Choke/throttle from oil cooler manifold (missing from the one in fitted on mine)
Exhaust brackets turned up

uses standard mount this side

and bolts to the HA mount on the other side

Really want the other bits to turn up now
flexi for the jx exhaust to afn turbo turned up today

still need a part for the oil cooler bracket, but i'm collecting that tomorrow
Good news! managed to collect this elusive part

That enabled me to fit the oil cooler bracket, cooler and filter

Then finished off the exhaust

Filled with oil and coolant, then i was able to do this click on it v

Scangauge showing revs, inlet temp, water temp and MAP, this was after some prolonged revving to bleed the system

Also got all my grills, bashplate and new dubflecta's on

Couple of little niggles, turbo leaked a bit of oil into exhaust from cold, but stopped when warmed up. Tempted to get it reconned for peace of mind, and the top coolant hose (head to reservoir) touches the top of oil filter housing, so need to find something to protect that.
Checked the fault codes, none
sorry for the rambling post, but thought i should update it, much happier with the van now, and AFN's are bloody quick
_________________
16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[lloydy]

Ecu and relays are being fitted in the little cupboard by the tailgate

New peddle

and a pointless shot of silicone hoses

_________________
16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[lloydy]

^^^ good link.
i went down the K&N route more for freeing space than anything else. I don't doubt the standard filter canister (esp with the dirt sep) will be more protective. Will maybe keep an eye out for some sort of in line dirt separator
_________________
16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[Outback Kampers]

K&N filters pass far more super-fine dirt than a quality paper filter and plug up faster. Off-road dusty travel will lead to faster engine wear using a K&N. Not a good scenario for an engine that sucks in a lot of air!

http://forums.nicoclub.com/debunking-the-k-n-myth-why-oem-is-better-t180100.html

I use only VW canisters like the JX or S. African 'severe duty' canister that uses the same filter element, or Donaldson canister filters. Not as small or cool looking but far more effective and protective.

_________________
Karl Mullendore
1990 Syncro 16" sunroof Reimo highroof conversion
1990 Westy Multivan 112i automatic
1992 LT31 Karmann Distance Wide 'La Tortuga'
2014 Touareg X TDI

[lloydy]

Hi, yep it's a K&N Apollo, do they not have good rep over there then? The size of it lends itself pretty well to the install. I do still have the jx syncro filter housing, but can't see myself putting it back in. As I think the battery tray will be in the way. Can't wait to get it back now, 5 days and counting then bring on those motorway hills......
Will hopefully be able to post some pics of the hydro mounts soon, just have to ok it with the installer. But as you can see from pics above, it utilises standard engine bars and the new parts just bolt onto them.
_________________
16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[BlackDogVan]

[Syncroincity]

Looks great... What filter is that?
_________________
'86 Syncro CHC Top AAZ Turbodiesel
'04 Passat Variant 4Mo 5MT

Vanagon Build: http://www.thesamba.com/vw/forum/viewtopic.php?t=466866&highlight=

[avdem]

Think i`ll copy that.....

[lloydy]

long time no post, will be getting the van delivered next week
here is a few pics i've been sent
engine midway through loom install

monster charge cooler radiator

and the lovely chargecooler itself

battery and air filter

_________________
16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[lloydy]

couple of pics of sexy engine bars, all set up for hydro mounts, and exhaust finished off

_________________
16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[lloydy]

Been a two week delay on this, my new 3rd and 4th gears were very noisy when my box was put back together. So a new set was ordered from USA.
All fitted in and is being shipped to the engine builder today have had a 1.09 3rd and 0.70 4th fitted with a 6.16 final drive.
Which will give me these rpm's

Not perfect, but dont plan on driving much over 65mph, and i like the off road ability of the 6.16's. Plus i can always increase tyre size if i feel i need to.
Engine wise, it's all kinda been on hold waiting for the box. Injectors have been rebuilt, and the new engine bars are coming along.
Hopefully the updates will be coming a lot quicker now, as i'm planning on picking it up on the 28th of this month. Have crazily volunteered to take four 11 year olds wildcamping for my sons birthday the following weekend
_________________
16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[BlackDogVan]

[lloydy]

[Zeitgeist 13]

Are those breather pucks available separately?
_________________
Casey--

'89 Bluestar ALH
'01 Weekender --> full camper
NEAT, no ICE.

[lloydy]

I've wondered that myself, thought it might be something to do with engine mount?
_________________
16" syncro multivan pop top AHU TDI
“Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life.”

[BlackDogVan]

On the crank case breather discussion, I had a nice little riser built from aluminum that allowed me to install the breather puck level as intended but above the block instead of the head. Then some tubing over to the breather on the valve cover. Worked like a charm. Breather puck at 50 degrees not optimal.

_________________
Gone but not forgotten - 1991 Carat - AAZ transmogriffied to mTDi.
Still addicted, looking for Doka...