Difference between revisions of "Betsy Bertha's m-TDI"
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=== Oil Pump === | === Oil Pump === | ||
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=== Oil Cooler === | === Oil Cooler === | ||
Revision as of 04:21, 12 February 2016
Contents
- 1 About
- 2 The Process
- 3 The Details (my collected research before above work)
- 4 Parts to Obtain List
About
So, my mechanical experience is limited to working on an 1984 gas VW Rabbit when I was 16 in 1996. I bought that car for a $1! Too bad it was totaled by a mini-van running a red-light.
I'm an IT (UNIX/OpenSource) engineer by trade, but I have been working on my 1982 1.6na diesel Westy since 2012. So, I'm geeky, but new to being a mechanic to my van as much as I can. Some stuff though (brakes/suspension) still gives me the willies to have someone more experienced do it; I had a bad experience with a brake caliper bolt flying off in m 84' Rabbit that scared the shit out of me!
In this regard I hope to get a decent engine setup after learning it and then take it to get the conversion done.
Reference Material
Here is my YouTube playlist of videos to this page
Parts Related
PartsBase.org 1997 VW Jetta - Part Information - 1Z/AHU
Service Manuals
VW; W42-011-294-103B
Bentley; ISBN 10: 0837603668
Forums & Social Media
The Process
This is where I'm going to linking to my youtube videos regarding my steps of building up a new-long block AHU engine using a used complete engine from Quality German Auto in Ontario, CA as a reference. Then the used engine someday will be either a backup/spare or for another project.
Here is the new long-block and used engine:
Bora Parts 1z/AHU long-block & Quality German Auto used engine - video
Bora Parts 1z/AHU long-block - video
Preparation
I bought two engine stands identical in the process of mounting the new long-block and the used engine onto for my work.
I first had to remove the clutch from the used engine to allow clearance with my mounting hardware to the stand.
Clutch Removal of used engine
Tools: 9mm 12-point socket & 17mm standard socket
Here is a photo of the 9mm removal
Heater Hoses & Engine Bracket Removal
The assembly is held together by some brackets and one nut head which can be seen below center photo between the two black hoses
Now remove this final hose
Now remove the other coolant hose
Videos
Here is the video I made of the part I took off:
Heater Hoses & Engine bracket - video
ECU / Wiring Harness
The side of the clutch top center there is a round cluster of wires and other plugs going into a central hub.
It looks like the below. I was able to disconnect everything but the glow-plug bar. I did the whole counter turn try and remove the plug, but no go. I just snipped the glow plug harness cable.
The rest I was able to unplug and the harness and all the wires came free:
What it looked like trying to get the two glow plug wires free
Videos
Video of what it looked like without the ECU wiring harness
ECU / Wiring harness removed - video
EGR Removal
You don't need the EGR! From what I have been told in the TDI Conversion list was the following from Karl M. @ link Westy Ventures: "In many early TDIs, EGR contributes a lot to the clogging of the intake manifold and ports. Many have deleted or blocked EGR on TDIs to avoid the buildup of nasty gooey carbon. There also is no easy way to control it on an mTDI."
Service Manual Reference
Bentley 26.1 - Exhaust System/Emission Controls
- Bentley 26-6 - EGR
- Bentley 26-8 - 1Z / AHU specific
- Bentley 26-9 - Fig 13.
Videos
Power Steering Pump & Bracket Removal
The power steering isn't needed for the mTDI setup in my 82'. To get the used engine close to what I need to work with, I'm removing it.
That can be done via three bolts. Two at the bracket and one at the swivel.
Service Manual Reference
Bentley 48.15
Videos
In the end after you remove the bracket bolts you'll just have the swivel bolt like below
Long Block (BoraParts) build-up
Engine Cover Plate
The new-long block didn't come with an engine cover-plate. This was purchased for the engine and the corresponding mounting hardware.
Reference:
I initially started with the 028109143H cover plate and the two bolts and washers that set it into place (N01021226 & N0122265)
These two 10mm bolts install at a torque pressure of 20n or 15ft/lb
Cover Plate
Where my thumb points is where the bolts go to mount the engine cover to the long-block
You see how it's mounted from the side:
Mounted from front
Intake
Tools:
Torque Wrench
Allen Hex Bit - H6
References:
VW; W42-011-294-103B 21-6
Using the reference above purchase the PD130 AJ Intake and associated mounting hardware.
If obtaining a used intake (which is MOST likely the case there's various methods of cleaning it out.
In my case, I used multiple (two-three days twice a day)power-washings after they sat with oven-cleaner sprayed on their intake ports.
It should look like this before putting it on the long-block
Blue coded thread lock used for mounting bolts
Bolt hardware installed at 25Nm (18ft lb) or close to that with a torque wrench
Gasket Install
The raised side goes towards the intake manifold with the indented side going towards the head
Vacuum Pump
Tools:
13mm open-wrench
Reference:
Before the video of the installation below, two things should be mentioned.
When installing the bottom vacuum pump o-ring washer 068145117B make sure it looks like the following onto the engine hole once you remove the old pump. I used some oil and a small screw-driver to help get it over the shaft.
Also add the other mount bracket o-ring washer N 90414601 onto the bottom of the vacuum pump
Videos
YouTube vacuum pump installation video
Final photos of installation
CrankCase Breather Valve
Tools:
Allen Hex Bit - H6
Reference:
Blue coded thread-locker was used on tube mount bolts.
Oil Filter Flange
Tools:
Allen Hex Bit - H6
Reference:
Video
Youtube - Installing Oil Filter Flange
Here is the oil filter Flange installed:
Oil Filter Union
References:
This is maybe the easiest part to install. You just screw it in. I put some blue thread locker on it. It doesn't matter which end screws into the oil-filter.
End result:
Oil Cooler
References:
Installation
This is pretty simple just screw in the (028115721B - union tube) into the oil-filter assembly.
Then place the oil-cooler over it and attach with the (068115723 - hexagon nut)
End result:
The Details (my collected research before above work)
There's a decent article on TheSamba about what parts you'll need
http://www.thesamba.com/vw/forum/viewtopic.php?t=410813&highlight=ahu+intake
What isn't needed from stock AHU Engine
If going mTDI the following are not required:
- electrical harness
- MAF sensor
- MAP sensor
- IAT sensor
- Injector #3 needle lift sensor
- Fuel temp sensor (inside IP)
- N75 & N18 valve
Air Filter
Donaldson filter G065433 install
Tranny Upgrade
The TDI won't have any difficulty cruising at 3500 or even a bit higher. The only downsides are noise and a bit of a drop in fuel economy. If your preference is to cruise at 65, then I would gear 3,000 @ 65MPH. With that gearing you will be able to cruise at 70-75 if need be and will still be high enough in the rpms @ 65 to develop enough HP for cruising with a 'cushion'.
Max torque on a stock TDI is around 2200 rpm. Max hp is around 3800 rpm. The TDI seems happiest in a Vanagon between 2600 and 2800 rpm. You are above the max torque, but well below the max hp. Your gearing and tires will dictate what speed that is. In this ratio, I would think a Westy would be more the range of 2700-2900rpm to account for the extra weight; ~700lbs last I heard!
Obtained a DK air-cooled transmission
Engine Mounts
http://www.thesamba.com/vw/forum/viewtopic.php?t=403215&highlight=ahu
rsxr - Saab engine mounts
Injectors
IDI Parts had the Bozzio Sprint 520's for around $175.00. They are supposed to be equivalent to the nozzles that came in the european delivered TDI's.
http://forums.tdiclub.com/showthread.php?t=276798&page=4
Clutch
http://www.vw-t3-bus-shop.de/en/19-tdi-modification-parts-for-vw-t3-bus
http://www.vw-t3-bus-shop.de/en/adapter-plate-for-turbo-diesel-gearbox-on-golf-starter -this adapter nicer than the switch a motor since its recessed for the starter alignment
http://www.vw-t3-bus-shop.de/en/clutch-dorn/gearbo...ion-to-org
http://www.vw-t3-bus-shop.de/en/abdeckblech-zum-schwungrad-aus-edelstahl
Intercooler
Water Pump Belt
http://www.thesamba.com/vw/forum/viewtopic.php?p=7673431#7673431
If you don't have A/C or PS, you can use the VR6 water pump pulley (028-121-031-E) and use the serp belt to run the Alt and water pump.
Oil Pump
VW p/n # 068 115 105 BP
NOTE: This is included in a long-block. I wasn't aware (my own ignorance) that a long-block included this. So, this is more a reference point for others in a similar boat.
Oil Cooler
http://www.thesamba.com/vw/forum/viewtopic.php?t=603839&highlight=ahu+water+pump
P/Ns:
027117021E cooler
028115721B tube
Exhaust
3 bolt ltr AAZ exhaust manifold 028 253 033S
Intake
The single large 3 bolt intake on the PD Intake Manifold that connect to your IC piping faces FRONT of the van typical on AHU install These terms are used to describe the same thing Driver side exit, right side , euro passat, longitudinal and is one of these part# 038129713AJ 038129713AG
Parts to Obtain List
NOTE: some of these parts you can obtain from the used engine. However, as I want to use the used engine for another project someday, I rather replace what I need for it on the new long-block. Everything below takes a Long-block 1Z/AHU as the base up to an installable engine.
I don't include pricing since that's a fluxing item whereas a part description / number won't.
Transmission
I'm starting with an 82' diesel, so I *have* to upgrade my transmission or expect to blow shit up early on.
I'd love to go 5spd, but not knowing enough to go this route, I have decided on a rebuilt DK (80-82 air-cooled Vanagon transmission).
I would assume "most" going to a TDI would really want to regear their transmission or swap out their transmissions.
Decision
Since each setup is different for me I decided on the following:
AA Transaxle - Rebuilder
My rebuild included:
- 3rd 1.12
- 4th 0.75
- LSD
For my tires my RPM ratios look like:
4.571 FD @ 0.75 - 2863 @ 65mph
4.571 FD @ 0.75 - 3083 @ 70mph
Engine
Misc
Belt Guards
Reference:
Bentley 15a-11
P/Ns:
028109143H - 1Z/AHU engine cover plate
Injection
The below are related to the injection system
Injectors
Injector #1 #2 #4 - 028130202P
Injector #3 - 028130202Q
Injector Holders
4 x VW p/n 028-130-206
Injector Nozzels
NOTE: What type of nozzles to use are more a personal preference of what you're give/take on the engine's performance you want to have.
Bosio PowerPlus 520 Injector Nozzles (set of 4)
Injector Fuel Lines
TDI AHU Steel Injector Fuel Lines - 028130301M/2M/3N/4N Injector Lines
Two sources I found new:
Crank Case Breather Valve Assembly
Reference:
PartsBase.org - Ventilation for Cylinder Head Cover Diagram
P/Ns:
1 x 028129101D - PCV/CCV Valve (A3) (B4)
1 x 028103491J - CCV Breather Tube (A3 B4 AHU 1Z)
1 x N 90466301 - o ring for breather tube
1 x 028103500 - CCV Valve Rubber Boot
Misc Brackets / etc
Below will list associated brackets that will need to be placed on the AHU long-block including any fasteners/hardware.
Oil Filter Flange
Reference:
VW Repair: W42-011-294-103B p13-10
P/Ns:
053115417A - Oil filter flange; This flange has been used for all the 1.8-1.9 gas and diesel engines (AAZ, 1Z and early AHU). The difference being the later AHU adaption have two 10mm ports and one 12mm port (for the Banjo Bolt N0210717) instead of the three 10mm ports that the gas/ABA engines use. There's no 'real' way to know which you get by searching for the P/N. Your best luck appears to be searching for a "MK3 TDI oil filter flange" or maybe "AHU" also in the search string.
There's also two other indicators of the proper one you received.
First the third port is larger than the first two. (photo coming soon of comparison)
The second visual indicator is a bit more positive you got the right one from what I have read on the forums and Parts Base.
Within the below photo in the red circle is 028115436 - choke; M12X1,5; AAZ,,AHU,1Z which is what you want for the diesel engines. From my research, and what I received the first time, gasser engines do not contain this.
- 1x 028115436 - choke; M12X1,5; AAZ,,AHU,1Z
- 1x N0160243 or N0160241 - sealing plug; M10X1; ADD,AHU,1Z
- 1x N0138115 - o-ring; 10X13,5; ADD,AHU,1Z
- 2x N0903151 - socket head bolt with hexagon; socket head (combination); M8X25
- 1x N90425401 - socket head bolt with hexagon; socket head (combination); M8X40; ADC,ADD,ACC,; AHU,1Z @ 25Nm
- 1x 028115441C - oil filter seal
- 1x 068919081A - Oil Pressure Switch [OEM] (A3)(B4)
- 1x N0210717 - Oil Filter Oil Feed Line Banjo Bolt
Vacuum Pump
References:
VW Repair: W42-011-294-103B p13-10
P/Ns:
1x 028145101A - AHU vacuum pump
1x N0102336 - hexagon bolt; M8X28 (13mm @ 20nm)
1x N01224110 - spring washer; B8X15
1x 028905256 - bracket
1x 068145117B - Vacuum Pump Bottom Sealing Washer
Alternator
VWDiesel.net Thread: W Terminal on TDI Alt
A AL0184X 120a alternator will work and includes a W spade
1997 Jetta 1.9 TDI alternator 90a
P/Ns:
028903119AA - Alternator Pulley
028903143AB - Alternator bracket
Glow Plug Goodies
028971766 - VW Early TDI 2 Wire Glow Plug Harness (’96-01)
0250202022 - VW 1Z AHU ALH TDI Bosch OEM Glow Plug Set ('96-03)
Clutch
Sachs G60/VR6 Clutch & Flywheel Kit (A4)(A5) [sachg60vr6a4]
[http://www.vw-t3-bus-shop.de/en/clutch-dorn/gearbox-input-shaft-tdi-golf-tdi-clutch-conversion-to-org Modified Bernd Jager TDI input shaft[
Bernd Jager TDI flywheel cover plate
Oil Pump
P/N:
068 115 105 BP
Oil Cooler
Reference:
P/Ns:
1x 028117021E - oil cooler
1x 028115721B - union tube
1x 068115723 - hexagon nut; ADC,AAZ,ABA,; AHU,1Z
Coolant Pump
Reference:
037121010AMY Coolant "Water" Pump; Complete with Housing; 30mm Hub
056121113A Thermostat; 80 Degree C; With O-Ring Seal
6PK1045 Serpentine Belt; Alternator
The Tank - Rocky Mountain Westy
Intake
Intake PD130 038129713AJ
I wanted to replace the gasket and all mounting bolts
ID Parts Intake Manifold Cleaning Kit (AHU/1Z)
Which includes the parts laid out in:
Partsbase.org 1997 Jetta Diesel Intake Manifold
The kit itself includes what I need: gasket & mounting bolts
Exhaust & Turbo
Four Hole AAZ Exhaust & flex down-pipe 3" & K14 Turbo
IC - A2A
SAAB Classic 900
Silicon Coolant Hose Kit
From BeeJee
VR6 Water Pump Pulley
P/N 028-121-031-E
