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1,9l TDI pumpe dusse vanagon conversion.
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jabba
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PostPosted: Tue Mar 16, 2010 12:53 am    Post subject: 1,9l TDI pumpe dusse vanagon conversion. Reply with quote

Hello vanagon fanatics Laughing
I'm searching for members who have done this conversion or kit from company to do the conversion.
Especially for the oil pan.
I've ever found solutions from hasenwerks, but they are no longer in activity and can't find the pics of their custom oil pan. Have you got it?
And from eurospecsport, but the kit they sale isn't for a 50 degree engine installation.
Please send me or post here pics of your tdi conversion.
Thanks for your help.
Stéphane.
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ThorAlex
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PostPosted: Tue Mar 16, 2010 2:12 am    Post subject: Reply with quote

What you need is a diesel donor van, in france that should be easy to find. the parts you need are: bellhousing, stub axle, oil pan and engine mountings.

That said the pump deuse system is supposed to be a bad choice (I can't remeber why), a regular TDi , is a better choice. Og to avoid the hassle of the electronics a 1.9TD (AAZ) is a good and easy conversion.
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jabba
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PostPosted: Tue Mar 16, 2010 3:24 am    Post subject: Reply with quote

Thx for your answer thoralex,
I know (approximatly) what i need for my conversion. Bt what i'm lookink for is pictures of such conversion for my reflexion.
A friend of mine have done this conversion with a 160hp tdi from a Seat Ibiza Cupra. And it's really..... WHAouuuuuuh! Very Happy
He had cut the oil pan like this:
http://www.casimages.com/img.php?i=090408112407623933450011.jpg

Hasenwerk have made a complete custom oil pan. I'm searching for other way to do the job.
In my mind, i would cut the tdi oil pan in 2 (in the longer side) and replace the vanagon specific oil pan on it with a strech band of metal.
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MarkWard
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PostPosted: Tue Mar 16, 2010 8:08 am    Post subject: Reply with quote

Jabba, do a search in the Samba Gallery under my user name. I have an ALH similar to the pump duse mounted at 50 degrees. We fabricated our own oil pan by cuting the flange "aluminum" from the stock TDI pan and welding in aluminum panels to replicate the 50 degree stock vanagon diesel pan. I like the look of the Eurospec kit and have been chasing a resonance/vibration they mention at a particular load and rpm. I don't believe Hassenwork has the pan yet unless they are making them one at a time custom. David Marshall had mentioned trying to do a run of pans from cast aluminum. I was interested, but don't believe he got that far.
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BlackDogVan
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PostPosted: Tue Mar 16, 2010 8:55 am    Post subject: Reply with quote

I'm pretty sure the fast forward PD was in a Syncro & at 15*.

FWIW I think the ALH is the best TDI VAG made. Easily makes the PD or CR hp, is simpler & can be run as a mechanical tdi.
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v.dubber
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PostPosted: Tue Mar 16, 2010 9:00 am    Post subject: Reply with quote

Loads of information on the Brickyard www.brick-yard.co.uk
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jabba
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PostPosted: Tue Mar 16, 2010 2:51 pm    Post subject: Reply with quote

@RSXSR,
I' ve saw a little piece of your custom oil pan on this pics:
Image may have been reduced in size. Click image to view fullscreen.

You've done a good job! Have you got pics during the built of your oil pan?
What kind of Clutch axle, fly wheel and gearbox did you use?

@BLACKDOGVAN,
Image may have been reduced in size. Click image to view fullscreen.


@V.DUBBER,
Sorry but i can't find informations on Brick-yard. Can you help me in being more precise.
Thanks each of you for your help.
Greets From France.
Stéphane.
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BlackDogVan
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PostPosted: Tue Mar 16, 2010 3:47 pm    Post subject: Reply with quote

jabba wrote:

@BLACKDOGVAN,
Image may have been reduced in size. Click image to view fullscreen.



You're not trying to tell me thats a PD, are you?
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jabba
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PostPosted: Tue Mar 16, 2010 11:50 pm    Post subject: Reply with quote

Razz No Blackdogvan it's not a PD engine, it's an ALH. But like rsxr says the 2 engines have the same oil pan.
It was just to show you that David Marshall have made custom oil pan wich can fit on PD engine for a 50° conversion. Wink
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wildenbeast
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PostPosted: Wed Mar 17, 2010 7:50 am    Post subject: Reply with quote

These places may also be of some help;
http://autos.groups.yahoo.com/group/TDI-conversion/
http://www.vwdiesel.net/forum/index.php?PHPSESSID=9d02d1704bda2f805cdedc6e44615853&
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MarkWard
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PostPosted: Wed Mar 17, 2010 8:16 am    Post subject: Reply with quote

Unfortunately, I did not document any of the work with pictures. This was a one off project started back in 2000. I am always more interested in getting a project done than documenting it. Usually, once I have completed a particular task, it seems I would do it differently the next time anyhow. Because of the extra work associated with using an ALH or PD layed over at 50 degrees, I don't know of many that are doing type of conversion in a vanagon.
For the transmission, originally I used a stock air cooled vanagon engine with diesel input shaft and bellhousing. After my second long distance trip, I decided to improve the transmission gearing. Daryl at AA Transaxle built me a new transmission from scratch with a 4.14 ring and pinion along with the updated 3-4 slider, his splash plates and a .77 th gear. I am using the stock diesel flywheel along with the stock vanagon diesel clutch. No signs of slipage yet, but I do shift very carefully. I learned from road racing not to stess the clutch. If I have a failure of the clutch, I will consider upgrading.
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Last edited by MarkWard on Mon Apr 12, 2010 8:48 am; edited 1 time in total
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BlackDogVan
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PostPosted: Wed Mar 17, 2010 9:43 am    Post subject: Reply with quote

OIC, yes I forgot they have the same block.

FWIW, for all the hassle i'd stick to a 1Z/AHU engine for a 50* install. Having a huge parts bin of stock install parts ready to go is really worth it now & down the road. The stock engine is good for the HP you're talking about with injectors and a turbo upgrade (you can reflash the ECU to run a VNT turbo). Thats already on the edge of what a VR6 clutch can hold & past that it gets pretty expencive.

I think the biggest upgrade in the ALH is better pistons (which can be used on a 1Z) & maybe slightly stronger rods. Not that the 1Z is known for throwing rods.

All that said I'm all for seeing a fire breathing PD in a Van, DO IT!!
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syncroserge
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PostPosted: Wed Mar 17, 2010 9:48 am    Post subject: Reply with quote

Stéphane, I sent you a message on T3Zone also. I have pictures that
can be of interest to all so I'll post them later today.
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jabba
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PostPosted: Mon Apr 12, 2010 2:50 am    Post subject: Reply with quote

Nip Tuck Laughing
Here is my custom oil pan:
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.
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SyncroGhia
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PostPosted: Mon Apr 12, 2010 3:44 am    Post subject: Reply with quote

A friend of mine has carried out his own TDi PD engine conversion in UK.
Here are a few pics...

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


He has made his own adaptor plate and mountings and runs the full dash etc in the van.

A quick quote from Doug
"The engine is attached to the gearbox using a custom made adapter plate, sorry no drawings or photos - you cannot see much of the plate when it's installed
The plate was made made so that the engine is vertical, the Europspec modified bellhousing would appear to cant the engine over, similar to the 1.6TD JX arrangement.
I completely rewired my van so that all the 'toys' from the Golf/Passat work including immobiliser, cruise control, adjustable wipers etc."

From memory, it's running about 160bhp but hasn't been dyno'd and he is currently working through clutch designs to be able to handle the power without slipping.

I'll see if I can get anymore info on it.

MG
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?Waldo?
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PostPosted: Mon Apr 12, 2010 6:33 am    Post subject: Reply with quote

jabba wrote:
Nip Tuck Laughing
Here is my custom oil pan:

Image may have been reduced in size. Click image to view fullscreen.


Nice pan, but why did you weld up the oil filler tube connection? Are you sure you'll never want to add one? A block-off plate would have been just as easy and at least given you the easy option. I suppose you can always cut the hole open again. Obviously fab work isn't difficult for you so it seems the oil filler would have been the way to go. I would make (and have made) a custom oil filler tube before I'd tolerate the hassle of pulling all the stuff out of the rear hatch to add oil. Here are a couple of pictures of one I made from a WBX tube (there's no stock filler tube that accommodates A/C).

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.
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jabba
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PostPosted: Mon Apr 12, 2010 9:28 am    Post subject: Reply with quote

SyncroGhia wrote:

I completely rewired my van so that all the 'toys' from the Golf/Passat work including immobiliser, cruise control, adjustable wipers etc."

From memory, it's running about 160bhp but hasn't been dyno'd and he is currently working through clutch designs to be able to handle the power without slipping.

I'll see if I can get anymore info on it.

MG

Yes if you've got more info. You are welcome.
I've got all the toys to. (immobiliser, cruise control...). But to make work the speedo i'don't know exactly what i need if you've got the info.
My engine (and all the "toys") come from a Seat Ibiza FR 130hp.
My friend who have done the swap with a 160hp from a Seat Ibiza cupra used the original cluth of the tdi (240mm). For this, he had to machine the original vanagon's bellhousing.
I think for my swap, i will try with a clutch from 1st tdi generation (228mm) and a disc from wbx. If it's not able to handle the power without slipping i will try reinforced clutch from a vr6/gti/G60.... Rolling Eyes
I'm curious to know what kind of clutch your friend is using and curious to see his dashboard.
Greets from French Atlantic coast. Very Happy
Stéphane.
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SyncroGhia
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PostPosted: Mon Apr 12, 2010 10:40 am    Post subject: Reply with quote

Ok I'll see if I can entice him onto the board Smile From memory, Doug uses an adaptor for the electronic speedo which fits directly onto the front diff.

Inicidentaly, an Audi MC engine uses a 240mm clutch with the same splines as stock...

MG
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jabba
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PostPosted: Sun Aug 01, 2010 10:55 am    Post subject: Reply with quote

Image may have been reduced in size. Click image to view fullscreen.



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Image may have been reduced in size. Click image to view fullscreen.

Many job to do again. Confused
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jabba
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PostPosted: Fri Aug 20, 2010 1:27 pm    Post subject: Reply with quote

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