Oh no! Another Vanagon TDI swap

[dieseltdi]

yes just email him or via his Facebook page.
_________________
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]

About the PD intake, easy to remove and replace when the engine is out of the car and the turbo isn't mounted. MUCH harder to do with engine in the car and with the turbo installed on a flipped AAZ exhaust manifold (puts the turbo nearly on top of the manifold and in the way of the bolts that hold the intake on). Also the ALH engine that you have combines the MAP and IAT into one sensor mounted in or near the intercooler. I would need to have a IAT bung attached to the extension piece of the intake. More money, more time, more effort. My inclination is to go the easy route so I don't have to remove any mechanical parts of the engine. I probably wouldn't notice the tiny increase in power anyway.
_________________
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]

Chris, it comes with some basic instructions for testing but you might need to do a search on actually turning on the cruise mine was already programmed for cruise and my harness was already wired for cruise. You also need some sort of VSS to feed the ECU. 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!

[MarkWard]

Different generation ALH, but enabling the cruise was simple using Ross Tech VCDS.

Unrelated, to the TDI owners, have any of you noticed the temp inside the van in the engine cover area after a long day of highway driving?

[dieseltdi]

I insulated the underside of the engine compartment, the engine lid, top and bottom and I have a mat of two layers of automotive carpet with rubber in between, then the westy mattress. This was done mostly for sound but it also doesn’t allow much heat to come through. I imagine that the old air cooled engines produced more heat than a TDI.
_________________
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]

Sounds like you’ve done a lot more. After a day at highway speeds the top of the mattress is warm. I think an air cooled engine by design was better at keeping the heat out of the actual engine compartment. I’ve got some ideas to maybe improve it. Was just curious if anyone else noticed it.

[dieseltdi]

Well after about 2 weeks of a renewed winter here in Texas, including 3 days in the teens with single digit wind chills, it finally warmed up enough to work on my intercooler relocation to the D pillar. I have moved all the boost and vacuum hoses, the N75 and the wiring. And have clearanced for the intercooler in the D pillar. I have mocked it up once but tomorrow I intend to do a mockup actually in the van so I know exactly where the intercooler needs to sit and how much cutting I need to do on my aluminum tubing. But as I was working with the original SAAB intercooler that I had installed (it has a crack and is damaged in other ways so it needed to be replaced) I noticed that there is a huge difference between the two. As you can see from the attached pictures, the old version has 10 rather large air pathways between the tanks with heat distribution fins between. The replacement has 15 pathways with fins in between. I can only think that this will have an effect on the air temperature as it passes through the intercooler! I didn't know that there were differences. Anyway, the other pictures are of the mock up of the intercooler in the van and then the mockup of how everything will be connected. Will see how everything falls into place tomorrow.

old intercooler

replacement intercooler

D pillar mockup 1

D pillar mockup 2

total system mockup

_________________
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!

[zuhandenheit]

Interesting that does look like the same intercooler I'm using, and I did not have the sheet metal interference behind the light.

[dieseltdi]

Couldn't get it in without clearancing that piece. I supposed I should measure both intercoolers. My replacement might be just SLIGHTLY larger. Will do that tomorrow.
_________________
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 interested in hearing how it performs! I know markward and a few others have cut out the bottom of the d pillar and generally report descent performance.
_________________
1981 VW Vangagon TDI (in progress)
1984 VW Rabbit Convertible (daily)
2003 VW Jetta Wagon TDI (recovering from a hit and run)

[AndyBees]

[dieseltdi]

Well today didn't go as planned. Yesterday I hurt my knee and was hobbling around today and really couldn't kneel down to do any work. I was. however, able to do a test fit of my mockup and almost nothing will work as I had planned. My U pipe isn't a tight enough bent and I can't TIG weld (nor do I have a welder) so it is out of the picture. Instead, I ordered 2 90 degree silicon connectors: a 1.75 to 2" for the intake manifold side (got this from Summit Racing and picked it up at my local to me store) and a 2"x2" for the connection from the IAT adapter. This one is a couple of days away from being delivered so I will wait out my knee and shipping to progress to the next step.I will use a small piece of 2" aluminum tubing to bridge between them. I think my connection from the compressor side of the turbo to the intercooler will work just need to shorten some things. Anyway, I will update when I get well (man I hate being old!) and the parts come in.

BTW I measured both of the intercoolers and they are the same size! No idea why I had to clearance the sheet metal and others didn't!
_________________
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]

duplicate
_________________
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!

[?Waldo?]

[dieseltdi]

Yes, I guess old is preferable to being under the ground by a whole lot.
_________________
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 I had hoped to get back to this WAY before now but what I thought was a simple deep muscle bruise on the area below the kneecap turned into full blow Bursitis and a lower leg that swelled up like an elephant's leg. Finally turning the corner now. I have done some preliminary work with stuff in the garage. I hope I can finally get back to this by Friday. Still, as has been pointed out, being old and easily injured is better that being under the dirt!!!
_________________
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]

Finally had a chance to work a bit on the intercooler install. Knee isn't 100% and I still can't kneel on it but it is bendable without pain. Anyway the intercooler is installed just need to make one bracket and then close it in so all the air coming down the air intake vent goes through the intercooler. Puller fan on the bottom will also make sure that happens. I have fabricated the turbo to intercooler hoses (in second picture) and will tackle the intercooler to intake on Saturday. Can't do much tomorrow as I have an eye appointment at 10 and then have to go and pick up some solar panels for my son in the afternoon. Plus the winds are supposed to be gusting above 50 mph tomorrow and I have to work outside. Anyway will post final pics when it is all done.

Intercooler installed

hose connections

_________________
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]

Plumbing finished!! Just have to tidy up some hoses and wires and do some sealing around the intercooler and it will be alll set. I started it up a few times and revved it up a few times to make sure no hoses shot off but it will require a full on the road test to make sure everything is correctly tightened. I am waiting on some breather hose to replace the heater hose on the valve cover breather. You can see from the picture how swollen it is from exposure to the oil vapor and it was really oily, on the outside, so time to replace. New stuff is fuel and oil rated rather than heater hose. I have also ordered enough that I might go ahead and install my Provent 100 oil vapor separator with a return to the block for the oil it removes. Will see. BTW anyone looking to do work with aluminum or steel boost or cooling tubing should buy a tubing bead roller. It saves a bunch of time and they can be had relatively cheap on that big auction site. I bought mine for about $30 shipped and it saved me so much time. I have a hand beader that looks like a big pair of wire cutters but with a big tooth on one side and a cut out on the other. While it can be used and will produce a "bead" of sorts, nothing like rolling one on this bead roller. Not what I would consider an expensive tool but definitely worth it. Anyway, I have included two pics of the bead roller. BTW it mounts in a vice.

_________________
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 finally got everything back together and all seems to be working well. I intend to spend several hours tomorrow just driving it at highway speeds to get a feeling on how the install stacks up to the way it was installed before. I can't help but believe that it will be much better than before. with a constant airflow coming down the air vent through the intercooler. I MAY at some point add some louvers to the bottom of the D pillar to allow better flow OUT for the air, especially since the fan runs all the time. Anyway one last picture with everything prettied up.

_________________
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]

took the van out for a long drive today to test everything out. First of all, the thing is much quieter now that I have the engine timed properly. I hadn't realized just how noisy it was. But beyond that, some actual numbers. With the intercooler mounted above the transmission, I would see intake temperatures that sometimes reached 240 degrees F on hard pulls and EGTs that would push 1400 degrees F. Definitely not seeing numbers like that today. I did a 100 mile on highway at 65-70 mph run to really get a feeling on the numbers. Anyway, highest intake temperature was 190 on a hard, full throttle, 17.6 psi boost, uphill highway entrance with an EGT of 1150 degrees F. Most of the time while cruising, the intake temperatures varies from 165-188 depending on the boost. Wind was howling today so sometimes just cruising I was pushing 13 psi of boost. Temps fell quickly when off the throttle. Just as a reminder, I am running a Stage 1.5 tune with 205 injectors so this isn't a stock configuration. I have a couple of things I wanna tweak for the intercooler but I am totally satisfied with the change. Now that my knee is finally healing up, I intend to install my new airshocks in the back and I have a set of rear wheel bearing housings that I am going to rebuild with new T3 stuff and then pull the rear drums, etc to install them. Then.....all the bushings front and back.
_________________
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!