Author Topic: at last more powers' insight (Read 2331 times)

wookey · « **on:** May 15, 2006, 11:08:20 am »

ok, a 1.7 diesel (non turbo) vanagon is plain dull, so i've bought a used 1.6 td from a '90 passat.

it seems to run well no knocks smoke etcetc, it has got 150K miles on it though.

before i put the engine in, is it worth the expense and time to do any work on it apart from a cam belt and general service? rebuild or a head gasket have been suggested but im from petrol land where 150k is alot! only concern is the extra stress the 2 tonne van has on the engine might kill it fairly quickly.

anythoughs advise more than welcome

cheers
wookey

RabbitJockey · « **Reply #1 on:** May 15, 2006, 11:53:03 am »

the gearing on the van is different, and in europe some vans came stock with turbo diesels. do the upgrade and enjoy the turbo.

Otis2 · « **Reply #2 on:** May 15, 2006, 06:09:33 pm »

And the gearing on a factory diesel Vanagon is different again.

I think you are going to find your existing gears too low for the turbodiesel engine. A lot of people who do the 1.6 NA to 1.6 TD swap also swap the transaxle from an air-cooled Vanagon (80-83 in USA & Canada). Keep your bellhousing from the diesel trans, and bolt it up to the air-cooled trans.

I think you'll have to modify the driver's side engine mount to accomodate the turbo on the Passat engine.

I believe the stock turbo on the original European-spec vans was a small K14, to keep turbo lag to a minimum in the heavy van. If the turbo on your Passat engine is the larger Garrett T3 or K24, you may find the lag to be ugly, unless you really turn up the fueling screw on the injection pump.

While the Passat engine is out of the car, pull the exhaust manifold off, and drill & tap it pre-turbo for fitting a pyrometer temperature probe. You must have a pyrometer in the van to tune the new engine for best power.

Final thought - what's your oil pressure, fully warmed up, spinning the engine at 2000 RPM? I believe 28 psi is minimum spec. That will give you an idea how close to rebuild you are coming. Intermediate shaft bearings and valve guides could easily be worn out a 150k miles.

wookey · « **Reply #3 on:** May 16, 2006, 04:48:21 am »

my 4 speed diesel gear box code is APF .. all the same ratios as a 1.6 td box apart from 4th 0,85

4th on 1.6td is 0,78 ABH code both the same 5,5 final drive.

will that have much inpact on my van?

will check out the turbo when i pick it up, and take a oil pressure guage with me when i look at it.

thanks for the heads up,

wookey

Otis2 · « **Reply #4 on:** May 16, 2006, 09:54:55 pm »

If 4th is the only different gear as between your NA and the TD van transmissions, then I guess the big issue is highway cruising speed. The secondary issue would be how wide a gap you can tolerate between 3rd and 4th gear ratios.

There's a T3 transmission calculator at http://www.syncro.ca/tiresize/

Assuming you have stock sized tires (and assuming that trans calculator is accurate), then at 4000 rpm, I think you will be driving about 65 mph with your present transmission.

The factory 1.6 TD van would have been travelling 71 mph at that same 4000 rpm.

My van does that same 71 mph at about 3600 rpm, by a combination of AAN waterboxer 4-speed and 27.5" tall tires. Very much less racket at highway speeds.

I run a 1.9 TD (AAZ) in this van, so I'm not sure if a 1.6TD van would drive as well with my high 4th gear ratio. The extra 300 cc in the AAZ may make the difference, as well as a couple of pump tweaks and a larger turbo on this engine.

Hopefully Mr. Brickyard and libbybapa will chime in, as they both run 1.6TD vans.

VentoTD · « **Reply #5 on:** May 17, 2006, 03:12:54 pm »

Sure it is an 1,6? I've never seen one without AAZ. Passat 1990 right?