ALH TDI in a 76 Bus

amosdoodle · Posted: Sat Oct 06, 2012 5:52 pm Post subject:

Here is a short video of the bus in action, vacuum pump cycling on as designed and start up. This week I worked on getting the vacuum system like I wanted it and slowly working on the electrical system. http://www.youtube.com/watch?v=18yjTyOtdUY&feature=plcp

tristessa · Posted: Sat Oct 06, 2012 8:51 pm Post subject:

Sounds evil .. straight pipe off the turbo? Twisted Evil

levi20AE · Posted: Sat Oct 06, 2012 9:43 pm Post subject:

looks like a great setup. how well does the radiator/fan setup work?
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amosdoodle · Posted: Sun Oct 07, 2012 5:23 am Post subject:

My exhaust consist of a 4 inch long down pipe at the moment. Eventually I would like it to be very quiet, just haven't gotten to it yet. The only other component Id like to have before exhaust is my rear mount set up.

So far I don't have any problems out of the cooling system I have been driving the bus up and down a private road. One of the things I still need to do is the electrical portion of the fan control module. Right now I have been monitoring temps through Vagcom and every thing is looking real good. The bus is driving really nice Very Happy

amosdoodle · Posted: Wed Oct 17, 2012 5:20 pm Post subject:

Small update, I have probably run two hundred miles on the bus so far. The original fan control module and wiring was way more complex than I needed it to be with the duel fan and to speed set up. The fan I have is a one speed fan and I ended up getting an 1980 rabbit fan control switch and using a heavy duty relay to turn on the fan, much much simpler. The switch is set to come on at 93c and go off at 87c and at the head outlet the fan is coming on at 95.5c which seems pretty good to me. The outdoor temperatures are very mild around here mostly around low to mid sixties. If I pull a pretty good hill and pull over at the top that usually is enough to get the fan to come on for about 30 seconds. Needless to say I am very happy with the cooling system, I know the true test will come in hot weather. Wink

The transmission gearing is very good and there is the beginnings of an exhaust system, just need to get the hangers figured out, that will be after the rear mount is completed. Right now vibrations are not the best hopefully the mount setup in the back will take care of some of that.

amosdoodle · Posted: Thu Nov 29, 2012 7:32 pm Post subject:

Alright I have traveled over 2000 miles sense re-powering with the TDI. We went on a couple of 400+ mile trips and it is nice having the extra range averaging 30 mpg on 100% bio.
Some of the things I have worked on sense last update are the rear mount setup. This made a huge difference in the vibrations for the bettor. There is still some resonating during acceleration that I would love to get rid of guessing it might be coming from my cheap air filter and exhaust setup.

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

The rear seat and bed cushions that were very ratty got redone the upholsterer did a great job on those.

And of course wiring and lose ends

The cooling system is working great a big part of that is because of the efficient radiator and forcing almost all the air to pass through the radiator

rubbachicken · Posted: Thu Nov 29, 2012 9:02 pm Post subject:

there really should be a really like button

Cool

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grandpa pete · Posted: Thu Nov 29, 2012 9:54 pm Post subject:

what kind of car did you get this engine from. what is an alh tdi Confused

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greenbus pilot · Posted: Fri Nov 30, 2012 2:27 am Post subject:

......So, your radiator fan must be running constantly at highway speeds?. Mine did. I did not think that was a good idea... Confused

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amosdoodle · Posted: Fri Nov 30, 2012 8:38 am Post subject:

Pete the engine came out of a 2001 VW Jetta Diesel, that series engine went in 99 through 2003 Beetles, Gulfs, and Jetta TDIs. Very good power plant regarded as one of the best VW or anyone else has made. Right now I don't know the percentage of time the fan is running but it is not all the time. With the moderate temperatures right now I don't think its running much at all because if I push it hard and cut the motor off the fan does not cut on until 10 to 15 seconds later. I know this is subject to change in warmer weather. A friend of mine suggested I put an led in the fan circuit so I could monitor the amount the cooling fan is running and buy the next update that will be in place. Vw designed the fans to run continuously with the A/C on some people never turn that off. Hopefully even in the hot weather I am optimisic that the fan will only run at slower speeds and higher loads. Fingers crossed we shall see Smile

CoastalAirCooledVW · Posted: Sun Dec 09, 2012 5:31 pm Post subject:

That turbo sounds awesome. Turn up the fuel pump to keep the tail gators away Twisted Evil

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Zelten · Posted: Sun Dec 09, 2012 8:43 pm Post subject:

That's a great engine. I have a 2003 TDI and I'm averaging 53MPG. This would be the engine I would put in a bus if I ever decided to swap out the Type IV.
Great job.
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amosdoodle · Posted: Mon Dec 10, 2012 6:50 pm Post subject:

I here you! It has been worth it, but I am also dealing with some of the decisions I went with like firewall to engine clearance. Everything is working but I am constantly looking for the best solution even if that means going in a different direction. That said this project has come together nicely and I am running a stage 1 tune Razz

avocado_tom · Posted: Thu Dec 13, 2012 9:24 am Post subject:

Awesome thread and thanks for all the updates. I've got a 1.6TD installed in my '71 but I'm still working out some of the cooling issues...I might have to pick up a radiator like the one you have...

Hope to cross paths sometime!

Krautski · Posted: Thu Dec 13, 2012 11:43 am Post subject:

I'm also interested to see the duty cycle % of that fan.

Usually those who put the rad there end up running the fan a lot, but a lot of them didnt bother with mutli pass rads or sealing it up.

Let us know when you find out.
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avocado_tom · Posted: Thu Dec 13, 2012 2:47 pm Post subject:

amosdoodle · Posted: Wed Dec 19, 2012 8:38 am Post subject:

Ok guys hold up on using the cooling setup for now. After doing some serious testing I am not sold on my setup as designed quit yet. More to come... Shocked

avocado_tom · Posted: Wed Dec 19, 2012 9:08 am Post subject:

Klaussinator · Posted: Wed Dec 19, 2012 11:45 am Post subject:

Just found this thread - WOW, great build!
I owned a Jetta with that engine and yes, they're a great little wagen-pusher. I've considered this before, mainly due to the fact that you can run on diesel, bio, or even grease with a few easy additions.

I'll be following your progress... I'm just up the road in Danville, VA

-Klauss
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1967250s · Samba Member Joined: May 02, 2007 Posts: 2137

Fascinating conversion. What is it like driving? Do you have a tach, and what rpms are you running at speed, say 60, 70 mph?
Considering where the radiator is mounted, I'm wondering if it gets enough airflow through it, since the engine compartment is open on the bottom. This would push air up into the compartment, slowing or even stopping air flow. Maybe if you mounted the rad in the right side where the battery is normally, cut a hole through the battery tray and close up the radiator in the compartment. Might have to mount the rad at an angle to get it in. This way, the air comes in the air intake from the outside upper vent, goes straight down and out the back. Another option is to cut some holes in the engine lid?
Great work there, watching!


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