Oh no! Another Vanagon TDI swap

[dieseltdi]

This is a test. I seem to be having trouble posting. Moderators?
_________________
When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[dieseltdi]

I have had trouble posting so here is the deal. I decided to swap out my Volvo oil cooler for a 30 row bar and plate cooler with a fan and a thermoswitch. The result was a 40 degree solid temperature drop from a bit over 260 degrees at time to now a solid 220 degrees or so.

"Kit" with all the necessary parts. I ended up using a different thermoswitch than the one pictured.

Cooler plumbed and fan attached

Thermoswitch

Fan mounted just forward of the passenger side jack support

_________________
When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[dieseltdi]

Managed to get around whatever glitch kept me from posting. Anyway, today got a really test of my TDI set up. To date, the farthest one way trip has been less than 100 miles with no problems. My trip today, from Grapevine, TX to Hutto, Tx for Harvest Fest was 200 miles both ways. Gave me plenty of time to observe temperatures and pressures. Since installing the oil cooler, I was expecting some solid results and I wasn't disappointed. Once up to temp. It stayed solid at 225 degrees F. That temp is from right out of the head so I am happy with my cooler set up. Oil pressures were 45 psi at 65 mph at that temperature. My two fault areas are in intake air temperature and EGT. During a hard long boost, the intake air temperature topped 200 degrees a couple of times and the EGTs reached around 1100 degrees (but ranged from 750 to 1100). My plan is to relocate my intercooler from above the transmission to the driver's side D pillar like many have done before me. It will clean up the engine compartment, put the intercooler in a constant air flow and make room for my rear sway bar setup using the old front sway bar. I also need to finally replace the rack and pinion. Will probably do that first while I am waiting on some hose couplings. Pics when I make it happen
_________________
When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[panel]

At what temp does the fan kick in ? (Sensor temp trigger )
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My '65-Subaru EJ20 Turbo conversion

[dieseltdi]

The Volvo plate opens at 190 and the switch is also at 180 (and off at 165) so they should come one together but in actuality it takes a bit before the metal of the switch heats up so there is a bit of delay.
_________________
When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[MarkWard]

Good proof of concept, but I would ditch the hose clamps and hose. Look at Earls or Aeroquip and assemble your own hoses with proper hose ends. It’s quite simple to do and won’t fail.

[dieseltdi]

AN fittings are nice but I like the hose barb fittings. The screw clamps came with the thermoswitch (also only available with hose barbs). When I do my maintenance and/or checks before a trip, I always look for seepage and leaks on hoses. then tighten those clamps that will need to be tightened. The oil hose I used is high temperature (400 degrees) and pressure rated but it will eventually have to be replaced, just like all the rubber hoses on the engine. That is the nature of the beast.
Hope to begin the process of R&R of the steering box tomorrow. We are having a bit of a resurgence of summer here in north Texas and working out in the sun has it limits but I need to do this on the driveway as my covered parking pad doesn't have a concrete slab just concrete tire runners with gravel in between.
_________________
When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[dieseltdi]

Another job done. I had a lot of play in the steering and I tracked it down to the bushings on the steering box. Rather than just replace the bushings, I purchased a new manual steering assembly from the Bus Depot. Anyway, today I removed the old assembly and discovered that my play wasn't just from the bushings. Both tie rods could be moved in and out nearly ¼"! That is a lot of slop in a rack and pinion set up. I spent a lot of time making sure that I got the new rack centered and then centered the old rack and measured the length of the tire rods and replicated that as best I could on the new rack. All that slack in the old rack made things difficult. Anyway got it all reassembled and man what a huge difference! At least 95% of. the slop is gone. The last little bit appears to be from the bushings on the steering column pins that hold the two piece collapsible steering column together. Those are on order and should be here soon. Only then will I take it to get aligned. I want to have all the slop out before they center the steering wheel and adjust the tie rods. Anyway, here are pics of the old rack after removal and the new rack installed. BTW, I purchased some TRW tie rod ends and they are greasable! Should make them last much longer. Also, don't be alarmed by the car stands in the second picture being really streched out. These were my secondary stands just in case something happens to the stands that are actually holding up the van. Cannot be too safe!

_________________
When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[ALIKA T3]

Don't worry too much about the centering of the steering wheel or replacing the little column grommets, it doesn't affect alignment, you can always pop the steering wheel last to straighten it, much less fussing.

Did you check the rubber couplers too on the column? There's 3 on the manual racks.
Get the OE ones only, sold by Febi. https://www.fcpeuro.com/products/vw-steering-shaft-flex-coupling-disc-251419417b

I would upgrade the rack bushings with PU bushings from Whiteline. T3 Technique sells them.
https://t3technique.com/collections/whiteline-bushings/products/whiteline-steering-rack-bushings

And lastly, you should install my silicone steering rack boots when these fail, bc they will
https://www.thesamba.com/vw/classifieds/detail.php?id=1837448

Aloha!

Alika
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Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget

[dieseltdi]

I did check the rubber couplings and they are both in great condition. I can grab the connecting rod to the steering rack and try to rotate it and it has absolutely no play. Just the upper column has that play in it now. I don’t know how I am going to handle driving the thing with out the looseness! Hayden
_________________
When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[dieseltdi]

Couple of updates: I eventually discovered that the rag joint at the base of the steering column (the one right on the front wall) was cracked and flexing badly. It has now been replaced along with the two rubber bushings on the interface between the upper and lower portions of the steering column. I still have a minor amount of play, maybe ¾", that seems to be in that funky 180 gear box thing. Not enough to require repair at this time. Secondly, I purchased one of those "mechless" stereos that have BT and CarPlay (wired only), FM and phone capabilities and mounted it on the lower heater cover with a housing. I kept my front door speakers that I already had and went OLD SCHOOL with a pair of NOS Radio Shack Bass Reflex 3 way speakers mounted in the back. I also moved the AC controls up to the lower edge of the dash where they are supposed to be. System sounds so much better to me but then I wear a hearing aide and I am mostly deaf in my right ear so.... anyway I attached a pic below. Next project: Replace my starter, big chunk of plastic broke off, still works but I am afraid of water infiltration. Replace the driver's side CV axle (cheap Ebay axles just didn't last). Already replaced the passenger side with O'Rielly lifetime warranty FCP parts. I also just bit the bullet and purchased a complete power flex suspension bushing set up from Chris at T3. I didn't need everything that comes in his normal kit so he put together one just for me. Great guy to do business with. Looking forward to loosing a lot of my squeaks once this job is done. Details latter.

_________________
When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[OlisGarage]

As always, nice and significant updates on the build!

If you get the T3 technique poly bushings, I also personally highly recommend the HD sway bar and also the steering rack cross member braces. They do make a difference.

However, I am not sure how much the 90° steering box slack can be made up for…


:cheers:
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1981 VW Vangagon TDI (in progress)
1984 VW Rabbit Convertible (daily)
2003 VW Jetta Wagon TDI (recovering from a hit and run)

[dieseltdi]

Already have the upgraded sway bar, endlinks and steering box stiffeners.
_________________
When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[dieseltdi]

Well back for another update. Van is running fine after a bit of trouble. See this: https://www.thesamba.com/vw/forum/viewtopic.php?t=799645

Today, I installed the new cruise control stalk that I got from that guy in Poland:

https://www.facebook.com/bogus.engineering [email protected]

The construction is very nice and the instructions that come with it are pretty good. I ordered one specifically for the AHU TDI swap but I think that he has versions for multiple engines, even stock. If you do decide to buy, be patient as he ships by boat, yes boat. Took nearly 3 months to get to me. I purchased the stalk and the two switches but decided to just use the brake and clutch switches I already had installed. Took it out for a ride after install and it works great AND every time. My old set, using a Mk 1/2 Jetta stalk, would work sometimes but not all the time and it would just sometimes cutoff and not resume. New stalk works perfectly every time I set it or resumed it.

Stalk and brake and clutch switches

Set Button

Resume (black button) and on/off (blue button)

In this setup, the default setting in ON but you can push the button to reset everything. Next on to the radius arm bushings
_________________
When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[dieseltdi]

OK, Now to the intercooler set up. I am going to put the intercooler in the driver's side D pillar with a fan that will run all the time. The first picture is of everything I took off my current setup that was mounted above the transmission. BTW good thing I decided to take this all apart as I discovered a crack in the plastic end tank of the intercooler that was leaking oil, and I am sure, leaking boost. Luckily I have another. Anyway, the second picture is of the EASIEST layout that requires me to only buy one new hose ( the hose from turbo to intercooler). This layout shows up a lot in various threads and allows me to place the IAT sensor very close to the intake inlet AND I don't have to remove or replace anything. The next picture requires much more work. I would have to replace the current intake and replace it with the PD140 intake and I would have to have an IAT bunge welded to the extension of the intake. Obviously, I need to do some measuring to get exact measurements but it is mostly getting the intercooler mounted first. However, I need to know which route I am going as the PD intake is taller and shaped directly that the AAZ intake I am currently using. BTW, I know that the PD intake is supposed to be better for power but that isn't my concern. I have tuned ECU, a tuned turbo and larger injectors already. Thoughts or comments appreciated.

_________________
When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[Chris-a]

[dieseltdi]

The set button wouldn’t be a problem but the resume right next to the on button might be a problem. Apparently he makes different styles so you might inquire?
_________________
When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[OlisGarage]

I’m using that same intake. I don’t see any reason not to use it. Less complex of a system and theoretically better flow. Why not use it?
_________________
1981 VW Vangagon TDI (in progress)
1984 VW Rabbit Convertible (daily)
2003 VW Jetta Wagon TDI (recovering from a hit and run)

[OlisGarage]

And that cruise control looks great!! I think I’m going to go that route. His kit looks to include basically everything and it uses the original Vanagon stalk. A genius idea.

Did you email him directly for it?
_________________
1981 VW Vangagon TDI (in progress)
1984 VW Rabbit Convertible (daily)
2003 VW Jetta Wagon TDI (recovering from a hit and run)

[Chris-a]

Second question, i assume you had to use ross tech vcds to flip some switches in the ecm to recognize the cruise? Or no??
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I gotta have nice tools, just look at the cars I drive.