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| | Decided on 1.9 (AHU) mTDI setup | | Decided on 1.9 (AHU) mTDI setup |
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| − | === 1.9 mTDI (AHU) swap ===
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| − | Garrett T2 and a KKK K14 turbo [http://www.thesamba.com/vw/forum/viewtopic.php?t=423496&highlight=diesel+conversion http://www.thesamba.com/vw/forum/viewtopic.php?t=423496&highlight=diesel+conversion]
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| − | Modify the Crank shaft to be a D-Crank [http://www.thesamba.com/vw/forum/viewtopic.php?t=525661&postdays=0&postorder=asc&highlight=aaz+crank&start=20 http://www.thesamba.com/vw/forum/viewtopic.php?t=525661&postdays=0&postorder=asc&highlight=aaz+crank&start=20]
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| | === Air Filter === | | === Air Filter === |
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| | [https://weddleindustries.com/products/new-products/new-vw-094-5-speed-kit https://weddleindustries.com/products/new-products/new-vw-094-5-speed-kit] | | [https://weddleindustries.com/products/new-products/new-vw-094-5-speed-kit https://weddleindustries.com/products/new-products/new-vw-094-5-speed-kit] |
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| − | == mTDI ==
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| − | AHU Engine @ 50 degrees
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| − | [http://forums.tdiclub.com/forumdisplay.php?s=3a783ecbf7ddbb6562f8f43af30e75b9&f=63 http://forums.tdiclub.com/forumdisplay.php?s=3a783ecbf7ddbb6562f8f43af30e75b9&f=63]
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| − | [http://www.vwdiesel.net/forum/index.php?board=5.0 http://www.vwdiesel.net/forum/index.php?board=5.0]
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| − | === Injectors ===
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| − | 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.
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| − | [http://forums.tdiclub.com/showthread.php?t=276798&page=4 http://forums.tdiclub.com/showthread.php?t=276798&page=4]
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| − | === Clutch ===
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| − | [http://www.idparts.com/catalog/product_info.php?products_id=764 Sachs VR6 Clutch Kit]
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| − | [https://www.google.com/#q=VR6+FlyWheel+bolts+OEM get flywheel bolts]
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| − | lloydy wrote:
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| − | shops over here as tdi input shaft. example below
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| − | http://www.brickwerks.co.uk/index.php/input-shaft-t3-tdi.html
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| − | For further info AATrans Axle on the NA side of the pond carry these custom tdi spline input shafts in stock
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| − | I had always understood HA project was the originator the modified input shaft
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| − | http://www.ha-projekt.de/index.php?route=product/product&product_id=61
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| − | and Bernd Jager has all the conversion parts for tdi starter adapter, the custom input shaft, & the modified dust shield if using the 22lbs tdi flywheel mounted to the dv bellhousing
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| − | http://www.vw-t3-bus-shop.de/en/19-tdi-modification-parts-for-vw-t3-bus
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| − | 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
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| − | starter alignment
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| − | http://www.vw-t3-bus-shop.de/en/clutch-dorn/gearbo...ion-to-org
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| − | http://www.vw-t3-bus-shop.de/en/abdeckblech-zum-schwungrad-aus-edelstahl
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| − | === Intercooler ===
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| − | [http://www.thesamba.com/vw/forum/viewtopic.php?t=582078&highlight=intercooler Saab 900 intercooler]
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| − | === Water Pump Belt ===
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| − | [http://www.thesamba.com/vw/forum/viewtopic.php?p=7673431#7673431 http://www.thesamba.com/vw/forum/viewtopic.php?p=7673431#7673431]
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| − | 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.
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| − | === Oil Pump ===
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| − | VW p/n # 068 115 105 BP
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| − | [http://www.thesamba.com/vw/forum/viewtopic.php?t=410813&highlight=ahu+intake http://www.thesamba.com/vw/forum/viewtopic.php?t=410813&highlight=ahu+intake]
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| − | === Oil Cooler ===
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| − | [http://www.thesamba.com/vw/forum/viewtopic.php?t=603839&highlight=ahu+water+pump http://www.thesamba.com/vw/forum/viewtopic.php?t=603839&highlight=ahu+water+pump]
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| − | 027117021E cooler
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| − | 028115721B tube
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| − | === Exhaust ===
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| − | 3 bolt ltr AAZ exhaust manifold 028 253 033S
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| − | === Intake ===
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| − | PD130 intake, MTDI, VNT17
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| − | 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
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| − | These terms are used to describe the same thing
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| − | Driver side exit, right side , euro passat, longitudinal
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| − | and is one of these part#
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| − | 038129713AJ
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| − | 038129713AG
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| − | === Parts to Obtain List ===
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| − | ==== Engine ====
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| − | $150 - SAAB 75 45 650 - [http://www.amazon.com/85-94-Engine-Support-Hydraulic-REIN/dp/B00U11LHB4 http://www.amazon.com/85-94-Engine-Support-Hydraulic-REIN/dp/B00U11LHB4]
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| − | Samba Article: [http://www.thesamba.com/vw/forum/viewtopic.php?p=7734114#7734114 http://www.thesamba.com/vw/forum/viewtopic.php?p=7734114#7734114]
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| − | === Obtained Parts List ===
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| − | ==== Used Doner Items ====
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| − | 053115417A - Oil filter bracket - $50
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| − | Set of used AHU Injectors with 0.216 nozzels - $100
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| − | ==== Alternator ====
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| − | 13461 - 120a Jetta 1.9 TDI alternator - $200 - autozone
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| − | 028903119AA - Alternator Pulley - $80
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| − | 028903143AB - Alternator bracket - $50
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| − | ====Glow Plug Goodies====
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| − | 028971766 - VW Early TDI 2 Wire Glow Plug Harness (’96-01)
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| − | 0250202022 - VW 1Z AHU ALH TDI Bosch OEM Glow Plug Set ('96-03)
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| − | 038911253 - VW TDI Glow Plug Relay ('97-01)
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| − | ==== Clutch ====
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| − | Sachs G60/VR6 Clutch & Flywheel Kit (A4)(A5)
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| − | [sachg60vr6a4] $359.00
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| − | Modified Bernd Jager TDI input shaft & flywheel cover plate
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| − | ==== Engine ====
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| − | Bora Parts AHU/1Z Long-Block w/harmonic dampener - $4103
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| − | ===== Injector Holders =====
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| − | 4 x VW p/n 028-130-206
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| − | ===== Injector Nozzels =====
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| − | Bosio PowerPlus 520 Injector Nozzles (set of 4) - $250
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| − | ====== Injector Fuel Lines ======
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| − | TDI AHU Steel Injector Fuel Lines - $250
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| − | ===== Oil Pump =====
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| − | VW p/n # 068 115 105 BP - $250
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| − | ===== Oil Cooler =====
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| − | 028117021E cooler - $150
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| − | 028115721B tube - $60
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| − | ===== Water Pump =====
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| − | 037121010AMY Water Pump; Complete with Housing; 30mm Hub - $80
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| − | 056121113A Thermostat; 80 Degree C; With O-Ring Seal - $10
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| − | 6PK1045 Serpentine Belt; Alternator; - $15
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| − | The Tank - RMW - $250
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| − | ==== Intake ====
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| − | Intake PD130 038129713AJ - $150
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| − | ==== Exhaust & Turbo ====
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| − | Four Hole AAZ Exhaust & flex down-pipe 3" & K14 Turbo - $450
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| − | ==== IC - A2A ====
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| − | SAAB Classic 900 - $80
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| − | ==== Silicon Coolant Hose Kit ====
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| − | From BeeJee - $450
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| − | ==== VR6 Water Pump Pulley ====
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| − | P/N 028-121-031-E - $50
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Decided on 1.9 (AHU) mTDI setup
Air Filter
Donaldson filter G065433 install
Tranny Upgrade
Obtained a DK air-cooled transmission
VW Gear Ratio
80-83 air cooled tranny
Tranny Comparison
Tranny explaiend
Tranny Information
jon_slider
hansj
Tristar Eric
rxsr
I use 225/75/16, stock 4.86 r&p, 1.14 3rd with .70 4th.
Yes there is a larger 3-->4 change but, for me, this is fine. I'd rather have the lower RPMs on highway.
1. Tallest Syncroghia, 4.57 R&P, 245x75x16 , 2nd ?, 3rd?, .7 4th
2. Shortest Tristar Eric, 5.43 R&P, 225x75x16 tires, 2.06 2nd, 1.14 3rd, .77 4th
3. Jon_slider, 4.86 R&P, 215x75x15 tire, 1.88 2nd, 1.08 3rd, .7 4th (I ran this config but wanted taller tires, the gearing was fantastic for my needs, both offroad and on highway)
4. Jon_slider, 5.43 R&P, 245x75x16 tire, 1.88 2nd, 1.08 3rd, .7 4th (this is my dream setup, next time I blow a ring and pinion)
1. Here is Syncroghia's speed @ 3000rpm in Granny, 9.61 mph, and in 4th 82.75 mph
2. Here is Tristar Eric's speed @ 3000rpm in Granny, 7.78 mph, and in 4th 60.90 mph
3. Here is Jon_slider's speed @ 3000rpm in Granny, 8.21 mph, and in 4th 70.73 mph
4. Here is Jon_slider's speed @ 3000rpm in Granny, 8.08 mph, and in 4th 69.64 mph
For reference sake, a stock USA gasoline syncro @4000rpm goes 10mph in granny and 70.9mph in 4th.
for my needs, my van is a daily driver with offroad capability, option 4 would work very well.
fwiw, I have also tried 4.86 R&P, 245x75x16 tires 1.88 2nd, 1.14 3rd, .77 4th.
speed @ 3000rpm in Granny, 9.03 mph, and in 4th 70.74 mph. This configuration is not ideal offroad, the highway gearing is fine. The lack of power between 1st and 2nd gear (when going uphill on dirt) makes me understand why people want to chip their diesels, but I would rather change ring and pinion, to save my transaxle.
rsxr
4.14 ring and pinion with a .77 forth gear and 215/65/16
Libby
Do you already have the engine. If you do not already have the engine, the AHU is a slightly better option as it has stronger rods. It's not a huge difference and the 1Z is a fine engine to use if you already have it.
The AHU or 1Z are both the same block style as the 1.6 (and AAZ) engines and so, the easiest route AND the best ground clearance will come from an install using the stock diesel vanagon mounting bits, bell housing, oil pan, etc... That will result in maximum ground clearance and no intrusion above the engine lid.
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'.
In Europe and Australia, there is a 4.14 ring and pinion available. Not cheap, and is sold for 5 speeds. It can be fitted to the 091/1 4 speed case though but not the 091 case. Daryl at AA Transaxle built me an 091/1 4 speed from scratch. He installed the 4.14 ring and pinion, the oiling plates, upgraded 3/4 slider and a .77 4th. Because he did not have a core from me it added up pretty quickly. I am extremely happy with the results. Not only did I improve 4th ratio, I got an overall improvement in all forward gears.
Now that I have some miles on it and am over the sticker shock, I wish I had him put in a quaife or peloquin differential while he was in there. Jon, I can appreciate wanting to detune the engine to get some reliability. With just the nozzel upgrade, I go very easy in first and second and don't really lean on the pedal until I am safely moving into third. I am sure the clutch will start to slip at some point, but so far so good.
RSXSR
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.
Engine Mounts
http://www.thesamba.com/vw/forum/viewtopic.php?t=403215&highlight=ahu
rsxr - Saab engine mounts
Constatine (562) 331-9146 was recommended by Thomas from QGA
Need tranny work
4.13 final drive
http://www.scangauge.com/
https://weddleindustries.com/products/new-products/new-vw-094-5-speed-kit
