vanagon conversion, gearbox, parts etc.

[friggerone]

Hi, greetings from Norway!

I've been searching this forum (and some others) and have not found the answers I need, can someone please help or poining me in the right direction.

I'm in the process of fitting a m-TDI engine into my vw t3 syncro 1990. The van only have lockers in the back. It's a 1.6 jx engine (it's an exchange engine, not aware of origin). The engine I've in my sight is a AHU 90ps, would like a AFN 110ps but they are further apart. The engine should be mounted tilted in 50 degrees. I've not checked what gearbox model I have.

225-75-16 bfg AT on 16-6 mefro rims gives 2600-2650 rpms in 100 km/h.

Do I need to change the gearbox with my setup, to a petrol one. And if so what's the recommended gearbox code?
OR
Is it recommended (possible) to rebuild my current gearbox with a higher 3th and 4th gear. Does anyone know of a good supplier of gearbox parts?

Do I need to install a intercooler right away?

What do I need to buy/dig out of spare-/new parts?
I've ordered the following (please feel free to fill in missing items):

Oil return hose (turbo)
Drive shaft for TDI-clutch
m-TDI pump
Bellhouse back plate

Does anybody have a cad-drawing/dimensions of the left motor-mount for self fabricating?

Here is a link to a Norwegian forum (via google translation) for those of you who're interested.

http://translate.google.com/translat...55%26t%3D24263

Best regards
Stian

[trailnewt]

Stian,

I am running about 2750 RPM at 100 km/h with my AHU TDI Syncro and am quite happy with the gearing. I think you will be happy with your current gearing. Petrol gearing will be too high for the TDI.

The common knowledge here in the USA is that you should install the intercooler right away. This is especially true if you are going to increase your fueling any amount beyond stock. Exhaust gas temperatures can get high pretty easily pushing around a heavy Syncro with increased fuel.

I don't know what the bellhouse back plate is, but if you are using a diesel t3 bell housing you shouldn't need any adaptor plate.

I converted from gas to electronic TDI so I can't answer your questions about what else you may need to convert from JX to manual TDI but, as I mentioned before, the Yahoo Groups TDI-conversion list is an excellent source for this sort of information.

Also the folks in the UK have a lot of experience with diesel Syncros.

Brent
_________________
'87 Syncro Westy TDI
Too many bicycles
Maybe an old unicycle around here somewhere

[SyncroGhia]

Hi Stian,

I would suggest higher gearing using both the 4.86 (or 4.57) final drive ratio and Albins replacement 3rd and 4th gears, the latter I would use atleast .77 or even a .73.

You need to find out which gearbox you have now.

Yes you'll need an intercooler with the engine. The most effective to use in our vans are water to air cooled rather than trying to get air flow though an air to air intercooler at back of a van where there is very little.

My experience of Tdis is with factory setups with ECU etc. M-Tdi engines can have very different torque delivery characteristics defendant on the individual pump and who's building it. The best way to find out what will suit your application would be with a dyno run so you have some figures and a graph to work from.

MG
_________________
T3 Syncro 16 S6 Westfalia Limey SOLD
T3 Syncro 6x6 SOLD
T3 RS6 Bluestar
T3 Tristar Syncro 16 SOLD
T3 Tristar Syncro RHD SOLD

[friggerone]

I was under my car today with a bronze brush and camera to look for the transmission number. It turn out I have a 091 AVK transmission, with the following specs (gotten from rjes.com)
AVK gear ratios:

G=6.03,
1=3.78,
2=1.88,
3=1.23,
4=0.78,
R=6.03
Final drive 5.43

It seems like I could use this gearbox, the final drive seems to be a bit high. Is it very complicated changing the final drive?
Think I'll place a order for a 350ps cooling set from frozenboost.com

By the way SyncroGhia, I really like your Limey rig.

[friggerone]

I want to install the tdi in 50 degree. I wonder if anyone have a (cad) drawing/picture of the left engine mount or some dimensions?