Betsy Bertha's m-TDI

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.

The service manual used; ISBN 10: 0837603668

Also use PartsBase.org 1997 VW Jetta

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.

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

Removing Clutch - video

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

Video of what it looked like without the ECU wiring harness

ECU / Wiring harness removed - video

Videos

ECU / Wiring harness - 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

EGR Removal Video

EGR Removed Video

The Details

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

Obtained a DK air-cooled transmission

VW Gear Ratio

80-83 air cooled tranny

Tranny Comparison

Tranny explained

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

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

Sachs VR6 Clutch Kit

get flywheel bolts

lloydy wrote: shops over here as tdi input shaft. example below

http://www.brickwerks.co.uk/index.php/input-shaft-t3-tdi.html

For further info AATrans Axle on the NA side of the pond carry these custom tdi spline input shafts in stock

I had always understood HA project was the originator the modified input shaft

http://www.ha-projekt.de/index.php?route=product/product&product_id=61

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

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

Saab 900 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

Oil Cooler

http://www.thesamba.com/vw/forum/viewtopic.php?t=603839&highlight=ahu+water+pump

027117021E cooler

028115721B tube

Exhaust

3 bolt ltr AAZ exhaust manifold 028 253 033S

Intake

PD130 intake TheSamba article

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.

Here's the ultimate price list of what I've bought. I may of missed a part here and there.

Engine

$150 - SAAB 75 45 650 - http://www.amazon.com/85-94-Engine-Support-Hydraulic-REIN/dp/B00U11LHB4

Samba Article: http://www.thesamba.com/vw/forum/viewtopic.php?p=7734114#7734114

Misc Brackets / etc

Oil Filter Bracket

053115417A - Oil filter bracket

1x 028115436

1x 028905256

2x N01224110

1x N0138115

1x N0160243

1x N0903151

1x N90414601

1x N90425401

Vacuum Pump Mount Bolt

1x N0102336

Injection

Set of used AHU Injectors with 0.216 nozzels - $100

Alternator

13461 - 120a Jetta 1.9 TDI alternator - $200 - autozone

028903119AA - Alternator Pulley - $80

028903143AB - Alternator bracket - $50

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)

038911253 - VW TDI Glow Plug Relay ('97-01)

Clutch

Sachs G60/VR6 Clutch & Flywheel Kit (A4)(A5) [sachg60vr6a4] $359.00 Modified Bernd Jager TDI input shaft & flywheel cover plate

Engine

Bora Parts AHU/1Z Long-Block w/harmonic dampener - $4103

Injector Holders

4 x VW p/n 028-130-206

Injector Nozzels

Bosio PowerPlus 520 Injector Nozzles (set of 4) - $250

Injector Fuel Lines

TDI AHU Steel Injector Fuel Lines - $250

Oil Pump

VW p/n # 068 115 105 BP - $250

Oil Cooler

028117021E cooler - $150

028115721B tube - $60

Water Pump

037121010AMY Water Pump; Complete with Housing; 30mm Hub - $80

056121113A Thermostat; 80 Degree C; With O-Ring Seal - $10

6PK1045 Serpentine Belt; Alternator; - $15

The Tank - RMW - $250

Intake

Intake PD130 038129713AJ - $150

Exhaust & Turbo

Four Hole AAZ Exhaust & flex down-pipe 3" & K14 Turbo - $450

IC - A2A

SAAB Classic 900 - $80

Silicon Coolant Hose Kit

From BeeJee - $450

VR6 Water Pump Pulley

P/N 028-121-031-E - $50