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Turbo Diesel JX engine
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nekto
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PostPosted: Thu Jul 19, 2012 5:30 am    Post subject: Turbo Diesel JX engine Reply with quote

i am in the process of installing a JX Turbo Diesel engine in my 82 Westy. there are two things i cannot find information on; how the air cleaner system mounts, and what powers the auxiliary water pump in the coolant line to the oil cooler.
any help would be greatly appreciated. i am very dyslexic and can't find this stuff without help. images would be a lot easier for me to read than words.
thanks
NeKto
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Mike Robinson
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PostPosted: Thu Jul 19, 2012 6:03 am    Post subject: Reply with quote

Good questions

It is worth joining the yahoo diesel vanagon group as there is a lot of information on diesel conversions there.

The original canister filter housing is not generally available in North America. It is a big round thing that fits??? behind the tail lights. Most people mount it behind the drivers rear light cluster. You can try quality german autoparts, they may have one. The other option people have used is a canister made by donaldson, this is a post from the tdi-conversion yahoo group

Re: TDI Air Box / Filter

P/N of the original donaldson airbox from the group buy in '07:
G065433

And here's all the details of the original group buy including the link to the
thread in the archives:
http://autos.groups.yahoo.com/group/TDI-conversion/message/10385


G065433 (air cleaner assembly, includes 1 filter element)
1-19 units: $94.67
20+ units: $75.73

P778810 (polymer mounting band)
1-5 units $8.87
6-25 units $7.98
26+ units $7.09

P822768 (replacement filter elements)
1-5 units $27.89
6-25 units $23.71
26+ units $18.69

You can also use a filter housing from a Dodge Minivan, 3l or 3.3l but it may be a bit small.

Plumbing from here http://www.siliconeintakes.com/

I am not sure about the aux water pump for the oil cooler. On a standard installation the oil cooler is looked after by the standard hoses. If you need a set of hoses you can get them from here www.greaseworks.com

Mike
'82 Wewty diesel AAZ
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kendalwoolf
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PostPosted: Thu Jul 19, 2012 10:09 am    Post subject: Reply with quote

Here are some pictures of the Turbo Diesel JX aircleaner installed on my 86 Vanagon.

Just the bracket can be seen in the left side of the image.

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


This picture below shows the filter housing mounded on the left side.

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


Larger pictures on my Picasa page
https://picasaweb.google.com/116740220905306898456/Vanagon16TurboDieselConversion#

The auxiliary water pump plugged into the harness that came with my engine. I believe it is triggered by a temp sensor on the head of the engine. My pump does not work and has not caused any problems just being plumbed in there, so you may not want to worry about it to much.
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ALIKA T3
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PostPosted: Thu Jul 19, 2012 10:40 am    Post subject: Re: Turbo Diesel JX engine Reply with quote

nekto wrote:
i am in the process of installing a JX Turbo Diesel engine in my 82 Westy. there are two things i cannot find information on; how the air cleaner system mounts, and what powers the auxiliary water pump in the coolant line to the oil cooler.
any help would be greatly appreciated. i am very dyslexic and can't find this stuff without help. images would be a lot easier for me to read than words.
thanks
NeKto


You don't have the harness for the electric pump,it's powered after the ignition is off if coolant is too hot.

if you use the 82 tubular engine mounts,the engine will be forward compared to original JX stock location,I don't know if this will be an issue to fit air filter,it's tight in there.
You might not have the holes in your body to fix the brackets,since the TD came around 1985 on the assembly line....
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minsk
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PostPosted: Thu Jul 19, 2012 1:33 pm    Post subject: Reply with quote

does the deck not need to be raised for this engine?
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?Waldo?
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PostPosted: Thu Jul 19, 2012 2:13 pm    Post subject: Reply with quote

The engine lid doesn't need to be raised for ANY turbo-diesel prior to the ALH (1999).
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nekto
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PostPosted: Thu Jul 19, 2012 2:54 pm    Post subject: Reply with quote

Thanks folks.
the photos of the JX air cleaner were very helpful. i have the whole JX set up; engine bars, complete intake, all the way to the tail pipe. and a 5 speed gear box as well.
good information about the auxiliary pump. i may figure a way to rig something up for that.
again, big thanks
NeKto
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CdnVWJunkie Premium Member
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PostPosted: Thu Jul 19, 2012 5:46 pm    Post subject: Reply with quote

Mike Robinson wrote:
Good questions

It is worth joining the yahoo diesel vanagon group as there is a lot of information on diesel conversions there.

The original canister filter housing is not generally available in North America. It is a big round thing that fits??? behind the tail lights. Most people mount it behind the drivers rear light cluster. You can try quality german autoparts, they may have one. The other option people have used is a canister made by donaldson, this is a post from the tdi-conversion yahoo group

Re: TDI Air Box / Filter

P/N of the original donaldson airbox from the group buy in '07:
G065433

And here's all the details of the original group buy including the link to the
thread in the archives:
http://autos.groups.yahoo.com/group/TDI-conversion/message/10385


G065433 (air cleaner assembly, includes 1 filter element)
1-19 units: $94.67
20+ units: $75.73

P778810 (polymer mounting band)
1-5 units $8.87
6-25 units $7.98
26+ units $7.09

P822768 (replacement filter elements)
1-5 units $27.89
6-25 units $23.71
26+ units $18.69

You can also use a filter housing from a Dodge Minivan, 3l or 3.3l but it may be a bit small.

Plumbing from here http://www.siliconeintakes.com/

I am not sure about the aux water pump for the oil cooler. On a standard installation the oil cooler is looked after by the standard hoses. If you need a set of hoses you can get them from here www.greaseworks.com

Mike
'82 Wewty diesel AAZ



Good post. Thank you. Any suggestions for a vendor to purchase a Donaldson from?
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nekto
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PostPosted: Wed Jul 25, 2012 4:20 am    Post subject: Re: Turbo Diesel JX engine Reply with quote

ALIKA T3 wrote:

You might not have the holes in your body to fix the brackets,since the TD came around 1985 on the assembly line....

You are right about that. any suggestions on where i should drill the holes?
i can see about where things want to go, but better measurements than eye ball would be a big help.
thanks for all the the helpful information Folks!
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alain riaud
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PostPosted: Wed Jul 25, 2012 4:30 am    Post subject: Reply with quote

If you need pics of a factory TD, let me know, I own one.
Speaking of the aux water pump, I suggest you fix it.
I have been told it's used to cool down the turbo after the engine is stopped.
Another tip: it's good to let the engine run few minutes after a hard drive, leaving all the stuff to cool gracefully.
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nekto
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PostPosted: Wed Jul 25, 2012 4:36 am    Post subject: Reply with quote

alain riaud wrote:
If you need pics of a factory TD, let me know, I own one.
Speaking of the aux water pump, I suggest you fix it.
I have been told it's used to cool down the turbo after the engine is stopped.
Another tip: it's good to let the engine run few minutes after a hard drive, leaving all the stuff to cool gracefully.

pics of the factory set up would be a big help. as an old school mechanic, it is good the hear people who know how to drive a turbo.
There is no wiring for the pump. powering it is easy. controlling it by using engine temperature is a challenge.
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alain riaud
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PostPosted: Wed Jul 25, 2012 4:50 am    Post subject: Reply with quote

nekto wrote:
alain riaud wrote:
If you need pics of a factory TD, let me know, I own one.
Speaking of the aux water pump, I suggest you fix it.
I have been told it's used to cool down the turbo after the engine is stopped.
Another tip: it's good to let the engine run few minutes after a hard drive, leaving all the stuff to cool gracefully.

pics of the factory set up would be a big help. as an old school mechanic, it is good the hear people who know how to drive a turbo.

[b]For that point, I'm not the right man, I blew two heads in 200 000 km.
This engine is very weak for this heavy van.
I calmed down and now I never drive above 65mph.
[/b]


There is no wiring for the pump. powering it is easy. controlling it by using engine temperature is a challenge.

Tell me what you are interested in.
I will have a look at this pump wiring.


Last edited by alain riaud on Wed Jul 25, 2012 9:51 am; edited 1 time in total
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nekto
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PostPosted: Wed Jul 25, 2012 9:42 am    Post subject: Reply with quote

alain riaud wrote:

Tell me what you are interested in.
I will have a lot at this pump wiring.

thanks Alain.
i could use a good look at the air cleaner mounting brackets, especially where they attach to the Van body.
as far as blowing head gaskets, don't feel bad about that. i blew one on an engine with less that 10,000 miles on it because i didn't know the head had never been torqued after it was installed in the 85 Jetta i got it from. warped the head at the same time.
and i use to be a professional mechanic! (on motorcycles and race cars)
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nekto
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PostPosted: Fri Jul 27, 2012 5:24 am    Post subject: Reply with quote

Andrew A. Libby wrote:
The engine lid doesn't need to be raised for ANY turbo-diesel prior to the ALH (1999).

actually, the boost compensator on the top of standard 1.6 TD engines will hit the engine lid. that is why the JX pump has a separate capsule that lays horizontal. i needed a little less that a half inch more clearance than i had. i solved the problem by putting a dent in the under side of my lid.
this is close enough that i would think some installations might just clear with no modification.
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nekto
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PostPosted: Fri Jul 27, 2012 5:30 am    Post subject: Reply with quote

Can anyone give me ball park measurements on where the holes are to mount the air cleaner brackets? i want to drill them before i put the engine in. it would be a real pain if i went too far one way or the other.
it look like i could get myself in real trouble if i go too low or too far aft. but i can't see where too far up or forward might be.
thanks for the help everyone.
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alain riaud
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PostPosted: Fri Jul 27, 2012 5:36 am    Post subject: Reply with quote

nekto wrote:
Can anyone give me ball park measurements on where the holes are to mount the air cleaner brackets? i want to drill them before i put the engine in. it would be a real pain if i went too far one way or the other.
it look like i could get myself in real trouble if i go too low or too far aft. but i can't see where too far up or forward might be.
thanks for the help everyone.

I think you are anxious.
I will take a picture of this air cleaner bracket today.
A picture with a metric rule, you will have to do the math.
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alain riaud
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PostPosted: Sat Jul 28, 2012 12:32 pm    Post subject: Reply with quote

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


Uploaded with ImageShack.us[/img]
[img]
Image may have been reduced in size. Click image to view fullscreen.


Uploaded with ImageShack.us[/img]
[img]
Image may have been reduced in size. Click image to view fullscreen.


Uploaded with ImageShack.us[/img]
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svenakela
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PostPosted: Sat Jul 28, 2012 2:06 pm    Post subject: Reply with quote

Vanagon JX 1.6TD pump:

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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nekto
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PostPosted: Mon Jul 30, 2012 2:55 pm    Post subject: Reply with quote

[quote="nekto"]
alain riaud wrote:
If you need pics of a factory TD, let me know, I own one.

Alain sent me some great photos. he posted some of them here. i got a very good idea of where the air cleaner brackets SHOULD go. then found my 82 frame wouldn't let me put the forward bracket where it wanted to be. but the information is good enough that i know what i might run into with the choices i have. there is a possible clearance issue with the intake manifold. i may end up making some spacers, and my air cleaner may tilt a bit. but i am confident i have things close enough that i can make them work.
big thanks, Alain.
i'll keep everyone posted as i get things put together.
thanks for all the help.
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nekto
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PostPosted: Thu Aug 02, 2012 10:59 am    Post subject: Reply with quote

nekto wrote:

i'll keep everyone posted as i get things put together.

Well, I've run into another "You can't get there from here."
anyone know where i can get an air filter element here in the States? my local VW Dealer is very good about looking up obsolete numbers. the VW number on the element i have (060 129 620) reads as dropped in 2009, no replacement.
there is another number that i presumed was a MANN number (45 114 54 154) but it makes no sense to the local independent European parts supplier. i talked to the head man at the local shop. he said MANN numbers should start with "C" and be shorter. they have a direct account with Mann.
so i'm stuck at the moment.
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