Betsy Bertha mTDI conversion thread

[rotaecho]

So, I haven't updated much on TheSamba, been on FB or my own website.

I ended up with DLC764's, because of a mishap with Kerma for the PP520's I wanted.

I also have a pair of 1019's I got from Casecade German I may play with.

I recently put on the GT2052 which if you compare the nozzle specs the DLC764 seem more fitted to the HP range of the turbo than the DLC1019's.

With the GT2052 I put on and recent tuning I can do 75mph up a 6% boosting around 18lbs and only be around 1050-1150F EGTs.

I may swap in the 1019's down the road to compare.
_________________
-Will
1982 Westfalia mTDI (50deg) aka Betsy Bertha
http://www.tdivanagons.com

[HBB]

I swapped out some Race 520 nozzles for DLC 1019's (Stage 2, modified pilot) and lowered EGT's by 100-400 degrees. The difference is, as you might expect, most notable on long mountain passes at highway speeds. I can now maintain 60mph on Snoqualmie Pass with EGT's at 1250 degrees, whereas with the larger nozzles, I was having to drop the speed down to 50-55 on the steeper sections of the pass.

My seat of the pants assessment is that I also gained some fuel efficiency, but I haven't bothered to actually measure.

The Race 520's that were in there were way to much nozzle, I don't know what the PO was thinking.

Good info on 764 v. 1019 in this thread: http://forums.tdiclub.com/showthread.php?t=472921&page=2

[erste]

Kerma suggested the DLC1019s for a vanagon because we're not pushing these things to redline. I think they said the DLC1019s make power sooner. The PP520s make more at the top end.

I don't know how the 1019s will work with your setup, but I'm happy with them on my chipped AHU.

Good info about the oil cooler, thanks for sharing.

[Outback Kampers]

I used the DLC1019 in my van that was sold and went to South America. Matt and Sarah reported they worked great even to 15,000' in Bolivia. I do know the EGT on those was lower than PP764 nozzles I had been running previously with the GT2052 turbo.
_________________
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

[rotaecho]

Okay! It's been awhile, and I figure it's time to update TheSamba to all the current events.

I am now currently on 62k on my conversion. Last November I ended up getting towed to Karl @ WestyVentures pad to repair a failed transaxle mainbearing replacement during the rebuild process at a pretty known shop. I was planning to visit and hang out with Karl anyways, BUT not under that circumstances :/

Anywho, besides that and a little stuff here and there (and a recent vibration I can't seem to pinpoint), the engine itself has been smooth!

There have been a few modifications and updates to mention though.

All the updates are at the website as well http://vanagondiesel.info

Okay, not sure if mentioned from the conversion process, but I was going for PP520 nozzles, BUT KermaTDI lost my injectors for three months then when they found them only had DLC764, so.... that's been my knowledge.

I'm debating going to DLC1019's or just the original idea of the PP520's. I have a spare set of injectors with me currently in the PNW I could drop off to Cascade German and plop either on. Then install them down there somewhere once I get them. I'm currently running Karl's 4bt IP (mTDI) pump to refresh the build notes.

I've been running my K14 HARD like 21psi at the max boost. The EGT's will climb to 1250F and hold and eventually back down when on 6%+ inclines. Crusing on highway I'm a round 450-850F depending on the incline (normal ups and down not 6%+). I don't drive like a race car; too blind for that, but up to 80mph isn't an issue. I don't mind pushing it hard once I'm at a certain speed. I generally cruise on highways 63-67mph.

In some instances not often I have reached 1350F; excessive LONG 30min+ super inclines. This is with the Renault 5GT A2A IC (Dual Core) tucked in the standard DS rear taillight location. VERY little modification needed and it fits like a glove. No way a fan would fit on it. However, in all honesty even in Yucca, AZ with triple digits in the summer, I never really worry about EGTs. Coolant temps & EGT's are the least of my worries LOL.

HOWEVER, there was one thing that did become apparent that I would care more about. Oil Temperatures! I hauled a 2.0 TDI engine from St. Louis, Misery to Mapleton, Oregon and my oil temps were pegged 260F and if pushing it hard a hair over 260F @ 55mph. Mind Betsy now is a hightop hauling my tricycle and last weighted was a total of 5550lbs. Without the extra hauled engine, my temps hover between 240-250F. If I pushed it hard 260F wouldn't be unheard, but it wouldn't go past this.

Now the previous stated was with the following modifications;

Aux Oil Cooler:

1x 028117021E - oil cooler V6 4Motion Cooler - Good for Stock AHU engines
1x 028117070B - oem cooler seal. The febi one sucked
1x 038117070B - oem cooler seal.
Get the tube & nut; same for both O/Cs
1x 028115721B - union tube
1x 068115723 - hexagon nut; ADC,AAZ,ABA,; AHU,1Z

I also implemented Karl's O/C modification;

http://www.vanagondiesel.info/index.php/Coolant_System#Aux_Oil-Cooler_Modification

Now, with Karl's modification, at 2.0 TDI O/C fit even BETTER! And my oil temps came down quite a bit. When hauling that 2.0 TDI, my temps went to 250F as my max. I can push 260F, but it's HARD to do. I was cuising 65-70mph easy. I'm VERY happy with this modification. I'll add photos in a few.

You need parts;

Choose an Oil Cooler:

1x 038117021B - oil cooler for a 2.0 TDI engine - Good for Enhanced AHU Engines
1x 028115721B - union tube
1x 068115723 - hexagon nut; ADC,AAZ,ABA,; AHU,1Z

I did grab a GT2052 that I plan on putting on, I have created a trapazoid to T25 adaptor that I'm going to use. Hoping this coming winter. The K14 isn't bad, but I want a bit more response and airflow. And . . . mid 20's boost wouldn't be too bad either

I'm really on the fence of the injector nozzles, I was using; https://www.myturbodiesel.com/wiki/tdi-nozzle-upgrade-fuel-injector-faq/

As a general guide, which seemed PP520/DLC1019 would be a good fit with everything. I don't recall if Karl used DLC1019 before, but I know he used PP520 before. Any experience here?
_________________
-Will
1982 Westfalia mTDI (50deg) aka Betsy Bertha
http://www.tdivanagons.com

[rotaecho]

Okay, giving an update here.

5000 miles on the new engine and loving it!

One lesson learned in a minor gotcha easily recoverable.

That is, use T-bolt clamps around the inter-cooler piping on hoses. I kept popping off the one connecting the turbo to the IC.

It would normally pop though when I hit around 22psi on the turbo (K14).

The diesel dash-cluster I created, had a defective speedometer (trip & odo don't work), and I think the tachometer from the MK2 CE1 cluster was also defective. It looks right at idle, but when you're moving it goes counter clockwise and locks up. I need to send those out to get repaired I believe. However, my MPGs are about what I expected (30-33).

Statistical info, my EGT's even on the most insane hill never exceeded 600/650F and on average I'm at around 400/450F crusing on the highway. Oil temps around 220-250F.

I generally cruse 60-70mph, but have rocked it up to 85mph a few times no sweat. The real sweet spot seems to be around 67mph on the engine hum which works for me perfectly.

Overall, I think total success.

Thanks everyone who contributed to the build!
_________________
-Will
1982 Westfalia mTDI (50deg) aka Betsy Bertha
http://www.tdivanagons.com

[rotaecho]

Karl, I think that turning of the fuel screw did it. I think it just backed out as you suggested.

I did some highway, city, and went camping in the mountains at around 5k elevation this weekend at Crystal Lake in Azusa, CA. About 130miles with a tad over half a tank; first real trip since fixing my speedo cable.

I never exceeded 650F on the EGTs and oil temps were about 220/230F. Coolant temps never moved.

Very well tuned IP Karl. It really makes that engine groove. Even the two times, where my IC & Turbo hose popped off (got a T bolt clamp on it now) and I had no turbo power, it hummed at 50 no problem. With the IC & turbo, up to 80 possible. Seems like 67mph is the sweet spot with all the various bits.

Still need to order the cluster foil kit when I get paid to get my tachometer cluster working. I'm curious about the RPMs.
_________________
-Will
1982 Westfalia mTDI (50deg) aka Betsy Bertha
http://www.tdivanagons.com

[rotaecho]

Didn't recall any issues with it on inspection previously. I'll check when light tomorrow. Since turning the fuel screw been driving fine. I haven't had a stall yet, but won't be driving much till this weekend.

I'm really digging that DMF Chris, you'll like it.

[Christopher Schimke]

I may have missed it, but have you checked to see if the accelerator cable isn't too tight and/or is moving freely?
_________________
"Sometimes you have to build a box to think outside of." - Bruce (not Springsteen)

*Custom wheel hardware for Audi/VW, Porsche and Mercedes wheels - Urethane Suspension Bushings*
T3Technique.com or contact me at [email protected]

[rotaecho]

The idle screw looked pretty solid. I the nut didn't turn any. It's a bit to reach, if I'm looking at the right one.

The fuel screw though, looked different than where I remember it being. About a quarter turn off roughly. I turned it where I figured it was, and snugged the nut.

I'll keep an eye on it.

Thanks!

[Outback Kampers]

Might be worth checking that the fuel screw or idle stop screw are both tight. One or the other may have back out.
_________________
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

[rotaecho]

Thanks Karl. It may be a bit longer on the tachometer. I swapped the pins over and remapped them for the proper setup. However, only the oil-pressure sensor worked. The ribbon of the 87 cluster is pretty tore up, so it may be a goner functional, just looks nice cosmetically. I'm looking at a few options for that. So the tacho is off the table for now.

However, a different test along the same pattern of the idle stalling when the engine warm happened today.

I did a 30min errand run around town. The engine when I pulled into the driveway had oil-temps of around 220/230F and pressure around 20psi, so it was warmed up. I had no stalling issues during that 30min period.

About an hour later, I went out to move the van back about 6ft. I could not keep the van idling at all. It just kept stalling if no fuel was provided. If I kept a little fuel on it, it idled fine.

Could this relate to that fuel screw I turned for initial adjustment? I turned 2 total turns already to have it not die on me on start and has felt/seemed fine in the cold weather. I did 2k miles without much issue. It did try to stall now and then, but it was hard to place my finger on it being consistent.

It's a little warmer now, so maybe the dynamics changed a bit.

I thought you said not to turn more than two full turns, but I have been doing the adjustments at quarter turns.

After the glow-plug light goes off when the engine is cold, it fires up within an instant.

Seems like a minor adjustment somewhere.

Thanks for any advice or suggestions you may have. I'm going to give it another start later this evening when the engine cools and see how it idles.

[Outback Kampers]

Keep in mind that once the tach is functional you'll still need an optical tach to adust it. There is a small hole in the back where you can reach the adjustment with a tiny flat screwdriver. The tach is adjustable because of varying pulley sizes on the belt drive.

I use one of these:
https://www.amazon.com/Neiko-20713A-Tachometer-Non-contact-Accuracy/dp/B000I5LDVC
_________________
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

[rotaecho]

[rotaecho]

Not sure yet, I'm in the process of wiring up the tachometer cluster I built.

[jackbombay]

EDIT- I didn't see the posts on the second page.

[Outback Kampers]

What rpm is the idle speed set at?
_________________
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

[rotaecho]

So, just following up with this. About 2100 miles on the engine so far.

I had another oil-pan bolt issue. Using the windage tray, I had to get some M6x25 bolts to have it fit properly. I started to have some oil-seepage with the old AHU pan bolts (way to short!).

That's resolved, and updated on the wiki.

Only one minor issue so far. When driving on the highway for a good period of time with the engine warm, if coming to city traffic off the ramp the van will stall at the stop-sign. If I give it some extra fuel a bit before going fuel idle, it is usally good. If I drive for about 10min within the city it goes back to normal and idles fine at stop-signs.

When cold, and going around the city/town in 3rd for a half hour or so around 35-40mph no idle/stall what-so-ever.

Something about the going highway speeds (4th mainly) and slowing down to city traffic.

It was recommended to use some diesel purge which may help.

However, everything else has been awesome. Loving the mTDI!
_________________
-Will
1982 Westfalia mTDI (50deg) aka Betsy Bertha
http://www.tdivanagons.com

[Zeitgeist 13]

I'm glad that turned out ok, but that must've been frustrating until it was resolved.
_________________
Casey--

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

[rotaecho]

One of the oil-pan bolts backed out which was near the flywheel. It backed out, fell into the bell housing, and rumbled around in there till it lodged in the starter & flywheel tooth seizing the engine.

It is also what made it feel like it as the crank that seized which in a sense it did LOL

The LUK 17-050 has a spot ground so you can reach those bolts easily. This time around I put some blue thread-tite and made sure it was tightened.

I had some help when installing the engine, and one of my friends mentioned needing to tighten those two bolts. With everything else going on, it got missed.

Super lucky SOB moment totally for sure. If it happened when going faster than 1st, it could have been a nightmare.

So far though, she's chugging awesomely