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1.9 TDI Tin top van from INDIA
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narendra.vw
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PostPosted: Wed Feb 05, 2014 5:47 am    Post subject: Reply with quote

rsxsr wrote:
I notice in the picture it is welded just below the mounting flange as well? What was the reason for that? Here is an adapter for the oil pan that requires no welding. Not sure how to buy one though.


Thank Rsxsr, I have been following your posts right from day one. Regarding first welding,I was hoping it to go unnoticed.
It was a mistake & later corrected.
I did go through the photos before deciding mine. These need CNC cutting &
professional Job. I went ahead with what was reachable to me. I still have photos downloaded from your post long back.
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bluefirefly
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PostPosted: Wed Feb 05, 2014 7:31 am    Post subject: Re: front view Reply with quote

narendra.vw wrote:
Yellow ones are Rally 2000. White Hella ones came with the van OE, was fitted on the Bumper which I relocated. Size similar to Hella 500. All carry 100w each.
Image may have been reduced in size. Click image to view fullscreen.


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


Such a nice looking van you have there.
I am really happy your are posting your mods.
No rush at all but please, keep them coming..... Very Happy
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PostPosted: Wed Feb 05, 2014 7:45 am    Post subject: Reply with quote

I like! Keep up the info and photos, very interesting!
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MarkWard
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PostPosted: Wed Feb 05, 2014 7:53 am    Post subject: Reply with quote

I am actually getting ready to start another conversion project. I have an 87 tin top syncro that I intended to rob parts from to swap to our 82. The problem is I don't really want to take the 82 down for a project of this size. I believe I can install a TDI engine into the syncro, sort it out on the syncro and then decide what to do.

I am shopping for a TDI donor and trying to decide if I want to use the stock diesel bellhousing, and adapter plate, or a Mexican upright bellhousing. Each has it's advantages.

Anyway thanks for sharing your build. It looks like a sweet ride and I bet it moves out really well. mark

PS. no worries about the pan. Mine looks homemade. Quite a few things on our van are 2nd or 3rd versions. If you search the member Jabba, he installed a PD TDI and documented how he grafted the diesel pan to the TDI oil pan flange. Came out really nice. Problem is you really only get once chance.

http://www.thesamba.com/vw/forum/viewtopic.php?t=404447&highlight=
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narendra.vw
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PostPosted: Fri Feb 07, 2014 7:36 am    Post subject: Reply with quote

Mr,blue firefly,
Thanks. Yes, mine will be in City limit Mode from now on. Very Happy (Photos looks better in different window. Please have a look. Thanks).

Mr,Gunldesnapper,
Thanks, for your encouragement.


rsxsr wrote:
I am actually getting ready to start another conversion project.
I am shopping for a TDI donor and trying to decide if I want to use the stock diesel bellhousing, and adapter plate, or a Mexican upright bellhousing. Each has it's advantages.



If you search the member Jabba, he installed a PD TDI and documented how he grafted the diesel pan to the TDI oil pan flange.

http://www.thesamba.com/vw/forum/viewtopic.php?t=404447&highlight=


Mr rsxsr,
If you have a close look, my oil pan is similar to Jabba. I did copy his Oil pan Mod while going through my Mod. Thanks to Jabba for sharing.
One small Info, please hold your horses until my next post. Very Happy It may help you while shopping in some way. Posting, coming week.


Last edited by narendra.vw on Sun Feb 23, 2014 6:54 am; edited 2 times in total
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narendra.vw
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PostPosted: Mon Feb 10, 2014 6:12 am    Post subject: Reply with quote

My Van’s TDI conversion in brief.

Past Details.
1990M Van, came with 1.6TD Engine, 5 speed Manual Gearbox & Manual Steering. (RHD).
Engine Code :-- JX. Gearbox Code:--WWO 091 301 103D. (Gear Ratio:-1st 4.11, 2nd 2.33, 3rd 1.48, 4th 1.02, 5th 0.82. R & P 4.83).

Present Details.
Now, it’s Enjoying with 2009M 1.9 TDI Engine. Engine Code:--ALH. 90 bhp. (Donor, Skoda Octavia, same as Golf’s ALH engine & layout). Engine mounted with TD mounts, TD brackets & TD carrier Bars.
Engine & Gearbox were Bolt on. No adapter plate used. Angle chosen 50 Degree.
Mileage, between 10 & 11 km/L.

Resent Work done.
1.Clutch Upgraded with TDI Flywheel, TDI Pressure plate & 228mm WBX 2.1 petrol Clutch plate. (I Thank Samba for this Mod).
2.Electrical Power Steering fitted few month’s back. Make NSK Japan.

Note:-- Most of the parts used were from VW family.

Preparation.

TD Turbo flange was separated.
Image may have been reduced in size. Click image to view fullscreen.


TDI Turbo detached from the exhaust manifold.
Image may have been reduced in size. Click image to view fullscreen.


The cut TD flange, welded carefully to the TDI Turbo body.
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My art in brush Painting. Very Happy
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TDI Turbo cleaned & reassembled.
Note:--Cutting & welding can be avoided if TD Turbo is used. Make sure it’s in good working condition. Mine was not. (TD Exhaust set can be used bolt on).
Image may have been reduced in size. Click image to view fullscreen.


TD exhaust manifold Direct fitment to the TDI engine. Hole made & steel pipe added for EGR connection. Hole can be avoided if EGR is deleted. Arrow shows where Turbo is fitted.
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TDI Turbo fitted to the engine with TD manifold.
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Turbo weight transferred to engine Body. Additional safety.
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All the above effort made my rest of the Conversion, smooth & easy. OE mounting Points for all the three. Two for the Engine, one for the Gearbox. Two mounting points were bolt on.

Gearbox Mounting
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Left side, TD Engine Mount & TD Mounting Bracket.
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TD Engine right Mounting Bracket.
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Coustomized Right Engine Mounting Bracket used. Reason, to make way for the ac pressure pipe coming out of the ac Compressor.
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AC hoses & Mounting Bracket can be seen.
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Gap between Carrier bar & the Roller. (Roller, the Part used in timing Belt for the same ALH engine).
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Roller Details.
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Shown in different angle. Note:-- Two Alternators are used. Alternator located bellow came with the engine. Since mine is EPS, the PS pump was replaced with 60A Alternator. This alternator charges the extra Battery placed below the Driver seat. Later matching Multi groove Belt was fixed.
Image may have been reduced in size. Click image to view fullscreen.


Gap between Body & Engine, App 1/2”. Arrow shows Unique simple Battery clamp.
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Battery Clamp. The other side of the Battery is press fitted to the existing OE channel.
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Engine Bay after Completion.
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Never experienced any heating problem with or without ac. Coolant level was always maintained. Never felt the need of condensation tank .Every bit of TD coolant hoses were used .
More details? Please let me know.

My Experience:-- Please look around your work place before you hit the Online shopping Button.
Hope, I have not pressed your sleeping button.

Thought of the day.
School door opens, Jail door closes.

Next, Air Supply.(No, not the song).
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narendra.vw
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PostPosted: Mon Feb 17, 2014 8:19 am    Post subject: Reply with quote

In my previous post, you may have noticed, parts used for ALH Engine mounting were from the TD van or TDI donor including fasteners. Same concept used in Air routing to keep things as simple as possible.

Air Routing.(Air filter to Inlet manifold).

K&N Universal cone filter used.

Air filter’s aluminum Sleeve ID reduced so that MAS is press fitted into it. By doing so, 1” gain in space for Air filter.
Image may have been reduced in size. Click image to view fullscreen.

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


MAS mounting bracket to the van’s body. The black plastic bracket is OE fitment for TD Air filter. (Part1shown in the Diagram bellow).
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Diagram.
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Details of Air filter to Turbo. TD. (Part 2 shown in the diagram above.). Flexible hose is from TDI Donor. Note:-- Two clamps are used. One clamped to Engine Bracket bottom. Other clamped to the Engine Head.
Image may have been reduced in size. Click image to view fullscreen.


To be continued.

Simple Mod

OE Bumper side cover extended. Now, side is protected. Part used from Suzuki Gypsy 4x4.

Image may have been reduced in size. Click image to view fullscreen.
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narendra.vw
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PostPosted: Thu Feb 20, 2014 6:32 am    Post subject: Reply with quote

Continued…

The journey of O2 starts from here.
Image may have been reduced in size. Click image to view fullscreen.


TD Hose clamped to TDI Turbo inlet.
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TD Hose Body clamped to the engine bracket. (Avoids strain on the TD Hose near the Turbo inlet).
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Turbo to Intercooler. (OE fitment for TDI Donor).
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TDI Hose going out of Turbo.
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Hose coming out of Turbo. Note the advantage for it’s narrow thickness.
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To be continued..

Van’s useful addition.

Mud guard cover, helps to protect inner wheel arches. ( Available in UK). Cost:- 17 GBP.

To fix, it needs one or two screws, rest is press fit.
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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narendra.vw
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PostPosted: Sun Feb 23, 2014 5:58 am    Post subject: Reply with quote

Mr rsxsr,

One small Info, please hold your horses until my next post. ... It may help you while shopping in some way. Posting, coming week.[/quote]

I am so sorry for showing wrong Emoticon, Embarassed My oversight, I thought it to be a wait symbol. I am new to this message body. I hope all you folks will pardon me. Thanks


Last edited by narendra.vw on Sun Feb 23, 2014 6:52 am; edited 1 time in total
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dobryan
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PostPosted: Sun Feb 23, 2014 6:30 am    Post subject: Reply with quote

Narenda.vw

Nice work!

(If you want to edit the emoticon you can click on the 'edit' button on the upper right of that post and then change it... Very Happy )
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narendra.vw
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PostPosted: Sun Feb 23, 2014 6:50 am    Post subject: Reply with quote

dobryan wrote:
Narenda.vw

Nice work!

(If you want to edit the emoticon you can click on the 'edit' button on the upper right of that post and then change it... Very Happy )

I am bit relived now. I will edit it. Thanks
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?Waldo?
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PostPosted: Sun Feb 23, 2014 8:16 am    Post subject: Reply with quote

You'd see an improvement in intake air temps and EGTs if you weren't drawing your intake air from the engine compartment and more specifically right above the turbo/exhaust manifold.
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narendra.vw
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PostPosted: Sun Feb 23, 2014 7:10 pm    Post subject: Reply with quote

Andrew A. Libby wrote:
You'd see an improvement in intake air temps and EGTs if you weren't drawing your intake air from the engine compartment and more specifically right above the turbo/exhaust manifold.

I agree with you 100%. Air filter has a protective aluminum fabricated shield bellow, but still, this Mod is for time being. Mainly I want to stop air sucking sound inside the cabin. I have checked the Air filter measurement which can be placed above the Intercooler. By doing so, it will eliminate sucking sound & due to side scoop more cold air for Air filter & Intercooler.

Air filter can be inserted only from outside making a 6”/7” removable scoop where side indicator is located. From engine bay it is not possible.

A small clarification , By keeping air filter above the Intercooler, face any negative reaction. Thanks.

Some idea for scoop
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PostPosted: Tue Feb 25, 2014 2:41 am    Post subject: Reply with quote

Ingenuity, your sweet ride must get lots of looks!
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narendra.vw
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PostPosted: Wed Feb 26, 2014 4:56 am    Post subject: Reply with quote

luVWagn wrote:
Ingenuity, your sweet ride must get lots of looks!


Thanks, Mr. IuVWagn. I feel privileged. Yes you’re right. I get appreciation same way what split Bus gets.

I live in a City where Vans are countable in Two Digits, I mean including all models. Most of them are always parked.

For me, finding was one thing, making was a whole other thing. Lost lot of family time.
In the end , I got my family time back with Interest. Very Happy

Air routing continued…

Finial work on Air routing.

ALH Intercooler. Please Note:--Intercooler comes as a stock part for the TDI donor.
Image may have been reduced in size. Click image to view fullscreen.


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


From Turbo to intercooler. (Please ignore the odd looking Paint job).
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Finial countdown.
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Completion of plumbing work.(Van has clocked 3000 miles with this mod).
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Add on. To enhance Front looks.

The Piece bellow the Bottom grill is welded to the OE Bumper. Two piece skirting is screwed to the Bumper bellow.
Image may have been reduced in size. Click image to view fullscreen.


Ready for Ramp walk.
Image may have been reduced in size. Click image to view fullscreen.


Your Opinion gives O2 to this Thread. Thanks.
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PostPosted: Wed Feb 26, 2014 8:07 am    Post subject: Reply with quote

Hello, I have to ask. A few pictures above you went to a lot of trouble to fabricate a custom exhaust manifold and followed up with a manifold that has a turbo mounting flange. I can tell from the pictures you are running the flybywire setup, but why didn't you use the ALH turbo or one of the available upgrades? Are they just hard to come by in India?

One of the plus points of our conversion is that I know if I need an engine part, I can order them from any VW dealer at least for now most likely over night. When you get into custom one off arrangements, it can make it more complicated to get back on the road if you have a failure.

I have a friend with a 5cylinder TDI in his syncro, it took a few months to get a replacement N75 valve and the one we ended up with had to be adapted. That particular engine never was sold in North America.

Great looking ride. I drove mine to work today, always puts a smile on my face. Good way to start the day.
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PostPosted: Wed Feb 26, 2014 8:58 pm    Post subject: Reply with quote

rsxsr wrote:
Hello, I have to ask. A few pictures above you went to a lot of trouble to fabricate a custom exhaust manifold and followed up with a manifold that has a turbo mounting flange. I can tell from the pictures you are running the flybywire setup, but why didn't you use the ALH turbo or one of the available upgrades? Are they just hard to come by in India?

One of the plus points of our conversion is that I know if I need an engine part, I can order them from any VW dealer at least for now most likely over night. When you get into custom one off arrangements, it can make it more complicated to get back on the road if you have a failure.



Hi, Good to see you back,

Bit of clarification,

Please remember, Van came with factory fitted 1.6 TD engine.

If you look closely the outlet Manifold Mod , I have used direct fitting TD exhaust Manifold to ALH Engine head. ID of TD exhaust & gasket is same for ALH Head. No modification on any Manifold.
EGR gas connection pipe is in same position that connects to ALH Inlet Manifold.

Work done.

ALH Turbo body separated from it’s Manifold. Cut TD Turbo fitting flange is fused into ALH Turbo body. Now ALH Turbo matches the fitting with TD Manifold just like TD Turbo fitting..
If you don’t want to spoil ALH Manifold & if TD Turbo is in Good working condition then Use TD Manifold with TD Turbo which fit directly. Keep ALH Turbo with Manifold for future use.

TDI Turbo failure means Turbine shaft or bushes are worn out. So Just change the ALH Turbo Centre Body. New one on eBay Cost app 120 GBP.
Please note:--The Only discarded part from TDI engine is cut TDI exhaust Manifold replaced with TD Manifold.

The Advantage we get from this Mod, TD engine Bracket, TD Engine mounting point, TD engine mounts, TD carrier Bar, all were bolt on. So no Engine Alignment problem. Simpler air routing, & many more

TDI ALH Turbo Centre Body.
Image may have been reduced in size. Click image to view fullscreen.


Hope, I have justified my work. Thanks for asking.
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PostPosted: Thu Feb 27, 2014 6:08 am    Post subject: Reply with quote

Nice work, enjoying the thread!
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narendra.vw
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PostPosted: Mon Mar 03, 2014 5:31 am    Post subject: TDI conversion Reply with quote

markd89 wrote:
Nice work, enjoying the thread!

Thanks Mr. Markd89. Hope follow up posts will do the same.

Drive by wire. (Accelerator pedal).

The pedal is from the TDI donor.
Image may have been reduced in size. Click image to view fullscreen.


Trying to make Ankle happy. The Angle of the pedal used to be with the cable, was maintained.
Image may have been reduced in size. Click image to view fullscreen.


Made a Groove on TD pedal. Bit of lubrication, it slides smoothly on to the TDI pedal rod.
Image may have been reduced in size. Click image to view fullscreen.


My experience, when a Driver seating position is Up right, no Acc pedal is comfortable other than the Pedal mounted from the floor.(Basically seated above the front wheel).

Before going to Exhaust system, I’m tempted to share this with you..

Lucky me, I hardly waited few minutes , Train arrived & in the direction I wanted.
Please open both in different window & close one by one..

How about for a size.
Image may have been reduced in size. Click image to view fullscreen.


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


Snaps were taken from DSLR Camera.
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narendra.vw
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PostPosted: Tue Mar 11, 2014 7:22 am    Post subject: Reply with quote

Exhaust system.

Similar to OE exhaust routing . No new additional part used. Recycle at it’s best.

TD complete exhaust set & a part of TDI Donor Exhaust set.
Image may have been reduced in size. Click image to view fullscreen.


After cutting, mixing, matching & re weld, I ended up with this. Note:-- TDI wired mesh flexible
pipe & TDI CAT included.
Image may have been reduced in size. Click image to view fullscreen.


A set of three parts in total. C Bend flexible pipe, Muffler with CAT & Thirdly, Bolt on TD chromed End pipe.

Since flexibility was achieved, exhaust pipe was mounted to the Van’s body. TDI Donor exhaust mounts were used.
Image may have been reduced in size. Click image to view fullscreen.


Photo above shows more Details.
Engine Mount, Mounting Bracket, Air filter to Turbo Inlet hose clamped at the top & clamped at the bottom, Outlet hose from Turbo to the Intercooler, Turbo to Oil pan drain pipe, Turbo valve & Turbo weight transfer Bracket to the engine body. (Note:--All parts have sufficient gap to each other).
Similar to OE?? Your thoughts on the layout.

4. Right side Rubber mounting. Additional rubber mount used. End pipe is bolted in such a way it makes an angle to the ground just like OE. Bikers will be happy while Van tailing.
Image may have been reduced in size. Click image to view fullscreen.


Space utility Mod.

Due to Sun roof Mod, the ac Air supply to the front Roof ac vents was cut off. Front ac vents were modified to store some useful things.

1.Two doors were fabricated. Arrow shows 1” C channel running full breath. Mainly to hold the doors & give strength to the plastic unit. (Looks like it want’s to communicate Laughing ).
2.A mini Blower was shoe honed into it. Fan speed is controlled by ac blower switch.
Image may have been reduced in size. Click image to view fullscreen.


Operational. Useful to keep Documents, Goggles, Hair brush, torch, DVD’s etc.
Image may have been reduced in size. Click image to view fullscreen.
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