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Engine Specific Info and Questions => TDI Engine -General Info => Topic started by: svenakela on December 24, 2009, 08:22:24 am
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Hi all,
I have a VW Transport pickup from -83 with a monster engine, 55 hp gives hard acceleration. ;)
I Bought a TDI engine a couple of days ago and won a Land Rover pump yesterday on eBay. As soon as I pick the engine up I'll start the mTDI-conversion.
The engine is from a Passat -96 and the pump is sucking air so I got it for a really nice price. The seller says that the head is replaced and the engine runs well. But now before the engine is out in the air, is there something I should check?
Regards,
Sven
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Hello Sven,
I would check/replace all the v-belts, and the timing belt and tensioner. Take off the intake manifold and clean the soot out of it. Thermostat & waterpump.
Find a place to mount the intercooler, most Transporter installations I've seen use a stock VW or SAAB air-air intercooler with a good fan on it.
Do you have the TDI-specific left engine mount? The original diesel motor mount won't clear the turbocharger... Brickwerks has them.
Welcome to the forum, and Merry Christmas!
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Ah, good note. I'll make sure to get the mounts as well. And a water pump, forgot that one. :)
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On second thought, contact Bernd Jaeger, you can get a better price in Euros at his site...
http://www.syncro-bernd-jaeger.de (http://www.syncro-bernd-jaeger.de)
http://www.syncro-bernd-jaeger.de/ENGLISH/TDI-Umbau/tdi-umbau.html (http://www.syncro-bernd-jaeger.de/ENGLISH/TDI-Umbau/tdi-umbau.html)
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Don't forget the idlers in the TB system. ;)
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Came home from a new years dinner (I'm already 2½ hours into 2010) and got the message from my English friend, "Got your pump, dude". Great! :)
The eBay-seller put the ad up with Pickup only. For him, not good. For me, perfect! How many guys in that particular area were looking for a Land Rover 300 TDI pump? Not so many I believe - I got it for the minimum bid. And luckily I got connections 20 minutes away and he promised to pick it up if I got it. And today he did pick it up! So, next week I have both the TDI engine and the LR-pump in the workshop and then I'll start the conversion right away. I hope I can manage to get some time to do it fast, but before the end of january for sure.
If anyone is interested, the pump serial is 0460 414 158.
(http://primenta.se/pub/vw/Landroverpump.jpg)
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Arrrgh!.. The package is still at DHL. But now tagged as "Damage scan". >:(
Haven't heard from them yet, so I don't know how to proceed. So typical.
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THat's too bad. Hopefully it'll show up in 1 piece.
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Got the package today. DHL did read the zipcode wrong, so they were looking for my street in wrong area. The package was damaged but with a quick view the pump still looks ok.
Finally I can go on, will pick up the engine now. :)
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Finally after some research I've found an engine I think will work. The turbo blew up and they just replaced the engine. The guy doesn't know if the engine sucked in crap from the turbine, but he has the turbo in the workshop so I can have a look at it when I pick up the engine. If it's damaged I can buy a head from another engine that was wrecked when a guy ditched his Golf.
Engine to the left:
(http://www.primenta.se/pub/vw/Thomas_TDI.jpg)
The one to the right...
(http://www.primenta.se/pub/vw/Thomas_TDI_2.jpg)
What do you think, good or anus?
It's a chance take. But a cheap one.
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Plan to replace the rods if the turbo went. They like to dump in lots of oil and hydro lock the engine. It's not a guarantee but it's a decent possibility.
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Plan to replace the rods if the turbo went. They like to dump in lots of oil and hydro lock the engine. It's not a guarantee but it's a decent possibility.
This is very true... :'(
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Ah, good info. Definitely something to look up.
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Sven, What sprocket are you using on the IP for your conversion?
I am trying to swap a Rover IP into an AHU engine as well. Here the small diesel engins are not so easy to find.
How are you timing your engine and pump?
Thanks, David K
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Hi,
Either I'll use the VW-sprocket or I make my own.
Timing, I'll do it the normal way I assume, measuring the advance.
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Thanks. I was a little bit worried about that, I had it deep in the head that another guy said that it should work with this engine. On the other hand, the sump didn't look like the AHU one so it isn't surprising...
I didn't know that ALH had another pattern, so that was very helpful. Then that motor has to go too. Darn!
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I was only thinking about the oil pan. :)
And yes I will go for the 50 degree mount so I need the original sump and pickup to fit.
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So do I need to remove the hub on the Landrover pump so the sprocket will work? Then make holes in the mount for the front of the pump to pivot for adjustment and set as for the Landrover? Change the outlet ports on the back of the pump as well.
Sven, if you need the VW pivot for the back of the pump I will be glad to send it to you, across the pond and puddle. This just saved me a TON(Metric Ton about 1.5 a US ton) of cash. If we all just played nice together the world would be a much nicer place. There are going to be some folks "building M-TDI pumps" real angry at this discovery cause I am going to post it all I can in the US VW diesel forums.
In rebuilding and modifing old autos we are our own WARRANTY and SERVICE DEPARTMENTS.
Thanks for your help fellows, David K
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The Landrover pump will run the engine. No black magic or voodoo involved. If this works out I will be looking for another 1.9TDI for my Westy soon. I put it on the back burner due to the nature of the swap an lack of transmissions. I only want to do the swap one time. I wish the little diesels were move available here in Texas. I am taking a bunch of heat for wanting to drive a Rabbit P/U instead of a F350 but the economy of the previous will tell the tale.
Andrew, Sven if you get out to Central Texas come vist. I doubt I will ever make it to Switzerland, but I have some nephews in Phoenix, Arizona. You never know it is a small world.
Thanks again, David K
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You are more than welcome to post the bracket, all parts are good to have. I have to continue the search for an engine though, as I need to have the original 50 degree mount and then the old oil pan must fit.
If you need some special parts for your Vanagon you could always send me a message, the Vanagons are pretty common here and I know a guy who buys them and slaughter them for parts sales (he has about 100 buses...).
If you ever go to Sweden, of course you're welcome to visit me. :)
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Sorry about the misdirection.
I ordered some parts from Germany a few months ago and WOW the shipping was high. If you need the brackets I have them from a spare 1.6 D. They will bolt on to the 1.9TDI AHU engine, the brackets on the AHU will work as well. That is what I have for my conversion. I am really thankful for your post concerning the Landrover pump as a mechanical pump for the TDI. I was looking at several different ways to run this engine using "custom built pumps". All expensive and what would you do if you need a repair? This way I can take it to the local Bosch repair and get it done as they will rebuild to Bosch spec. I can make the adjustments.
If you have a MIG welding machine you could fabricate an oil pan for the ALH. I have done a few custom pans for other cars where clearance is a problem. It is real easy if the pan is made of steel. You have a basic template with the exhisting pan on the VAN. You could even increase the volume of in the pan(is more really better?). The metal must be clean and fit tight at the joints. You could hold it with sheet metal screws(clecos)then weld it remove the screws and weld the holes. Just a thought.
Many Thanks, David K
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The reason why I want to keep the original oil pan is to avoid problems with the MOT, specially as my conversion will be about 225 % power increase. I want to "hide" the new engine a little bit... :)
I'll see if I can find an AHU. This engine would be very nice, but now I want an easy setup. I have no problem with fabricating new pans etc, I have two fully equipped prototyping workshops. Right now time is an issue though.
Of course I'll keep on posting about my LR pump setup.
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My $.02 on the sprockets, I got the ALH style adjustable sprocket to fit perfect by machining a AAZ IP bracket to for the nose of the LR pump & by removing the LR bushing & using the ALH shaft bushing.
(http://images.thesamba.com/vw/gallery/pix/557862.jpg)
(http://images.thesamba.com/vw/gallery/pix/557863.jpg)
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My $.02 on the sprockets, I got the ALH style adjustable sprocket to fit perfect by machining a AAZ IP bracket to for the nose of the LR pump & by removing the LR bushing & using the ALH shaft bushing.
(http://ALH)
(http://ALH 2)
It looks like you have the ALH on 50 degree, or is it just the workshop stand?
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Look at the water pump. BDV's is either an 1Z or AHU with LR pump.
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yes you need the alh pulley and hub to do it, although i never tried a tdi sprocket directly onto the LR shaft, i can get one and have a test fit sometime next week. I'll report back!
Ruben has an AHU i think
look here for the rear mount, i never looked far for a bolt on effort but i'm sure a 1.6d has the one you would need
http://forums.tdiclub.com/showthread.php?t=255267 (http://forums.tdiclub.com/showthread.php?t=255267)
Ry
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Look at the water pump. BDV's is either an 1Z or AHU with LR pump.
Those details. Too tired, need more beer.
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Its about as franken motor as you can get i think...
AAZ block
1Z head
AZZ cam
ALH pistons (nural ASV)
AAZ crank with AHU/1Z Crank pulley mod
AAZ IP bracket
LR 11mm pump (just back from Giles massage) with ALH sprocket
tdi single mass flywheel
vanagon clutch disk
VR6 pressure plate
PP520 nozzles (thanks Ryanp)
turbo TBD (GTA2056V, GTB2056V or a WG hybrid)
MANN CCV filter
Amsoil bypass oil filter
Maybe a PD intake.
All sitting on an engine stand mocking me..........
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All sitting on an engine stand mocking me..........
HAHAAA, Yeah me too. I hope you're going to some Olympic events... Good luck!
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Its about as franken motor as you can get i think...
Do you have any thread here at the forum about the engine, or could you enlighten us with more details?
I'm really curious to hear more about that very-Franky-setup, specially why you chose the head/engine/block. What rods did you use?
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Well it all started out as rebuilding my current AAZ into an mTDI. An abandoned mTDI build came up for sale near me so I grabbed it to build up & keep my van on the road. Turned out to be seized with broken rings in 2 cylinders (glad i pulled the head) so new rings & a line bore on the main & its good now. I was happy to find it because it is the exact same thing I was going to do with my AAZ. It has AAZ rods & crank, strong enough for the hp I hope to take out, 135hp/250ftlb. Its going in my 91 Vanagon using the 50 degree diesel mounts & bellhousing. Then I found 2 LR300 pumps on uk ebay, one was crap one perfect (got a refund on the bad one, great LR parts guy) & sent it to Giles for his tweaks. FYI he was REALLY excited about the LR 11mm pump performance on his test bench.
The hold up now is finding time to install an air water IC setup, thin rad up front, core above my tranny & a VR6 aux coolant pump to run it.
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Finally it seems I've found a seller that's trustable!
He got one Vento -95 and one Golf -96. Both are 1Z, the Vento engine is already out and he said it was working fine (180 000 km). The other one was starting but there's something with the turbo. It was not out, but I can take everything I want from it. So I'll simply take everything I can remove! :)
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Finally! :)
Took a 2,5 hour drive through the crazy winter storm to the guy with the 1Z engines. He was really a nice guy, but he hates winter more than I do, so he rather gave me a good price on the stuff than helping me in the fekkin cold. :D
I had to do all the unmounting outside. The engine was already out but the gearbox was still on. The second engine was still in the car so I had to take the parts from there. -14 Celsius isn't too bad after all. Winter boots and a good jacket makes it all. I got a complete engine with pump and turbo, one head with all the stuff still on including the turbo, a 120 A generator, a filter box with the MAF and the inlet pipe, and last an intercooler with all the pipes from two cars. All that for less than US $366, or CAD $388.
You should see his Chrysler 300 -66 that was in the workshop, a real jaw dropper!
Yes, we do have winter:
(http://www.primenta.se/pub/vw/200221_getting_engine.jpg)
Going home:
(http://www.primenta.se/pub/vw/200221_parts_in_touran.jpg)
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Could you send pictures of the serpintine belt idler and how it mounts to the engine? I need the idler for my engine and am trying to decide if the idler off a gasoline engine will work as they are more plentiful here in the recycling yards.
It LOOKS cold in those pictures. If it thinks about snowing here they shut everything down.
Thanks Sven.
David K
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Ok, you won't believe this - because it's F**KIN' unbelievable.
Was going to drive to the garage today with the VW, went out on the street just to realize it's stolen!
Who the hell steals a 28 years old a VW pickup?!
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Wow, sorry to hear about your misfortune. Hope you have proper insurance. Maybe luck will be on your side and it will be returned. We had our old shop truck stolen years ago when thieves broke into our shop and needed a getaway vehicle for their "proceeds". Well they drove 50 miles and stopped to put gas in the diesel truck and couldn't get it going- damn fools. I always wondered how they got that old 6.9L IDI International engine going without the GPs in the middle of winter! We got the truck back, and maybe you will too.
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I hope so, it was pretty hard to find a single cabin with a diesel. :(
There are only two diesels for sale at the moment, they are both cabin crews and at least 600 km away.
I really do hope I get it back. Here, over 90 % of stolen vehicles are found, so there's a good chance. I hope they don't wreck it though,
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She's back.
The Police called me yesterday and said the car was on a street not even a mile away!
The door lock is now unlockable with anything and the ignition key cylinder is ripped off. And they stole... ...the bloody battery!
F**kin druggies.
Why the hell did they drive 1000 m away to steel the battery, why not do it where it was parked and not damage the car?!
Now I'll remove the door locks and buy a remote controlled central locking instead, found 'em cheap on ebay. And a car alarm.
At least, soon back on track!
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Glad to hear you got your rig back. Damage doesn't sound too bad either which is fortunate. Maybe consider installing a remotely mounted kill switch too.
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Well, everything's not legal here...
South African Car Flamethrower (http://www.youtube.com/watch?v=fDrzMGdYWZc#)
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Got to do an update.
We've been working with the new garage for months but finally we have moved into the new place (It's eeh... ..kinda uge...). When we made all the walls, the pickup went many times to the brickyard. And daaarn they're loading! Here's a complete pallet of OSB board, almost 1.3 ton. The heaviest loading I did was 1.9 ton and still she went home like normal. Ok, it's a bloody slow vehicle, but with full load it keeps the same speed. :)
(http://primenta.se/pub/vw/1.3_ton_osb.jpg)
The AAP gear box is cleaned up, zinc primed and then painted. Nice to work with until it's into the pickup and way easier to keep clean later on. Now it's just waiting for the diesel bell housing.
(http://primenta.se/pub/vw/aap_gearbox.jpg)
Rims are cleaned as well. Did try to make them in our own sand blasting box but it took too long time. I'll send these to a company that will make it cheap. Then, black paint!
(http://primenta.se/pub/vw/passat_rims_16.jpg)
Finally, just ordered a central locking kit from eBay, time to fix the locks that the bloody druggies damaged. A new ignition key was fixed via a friends VW workshop. I'll use two locking motors for the doors and two for the hatches.
This was dirt cheap, and there are several with even lower price. In the UK though, but I'm sure you'll find them at ebay.com as well.
(http://primenta.se/pub/vw/centrallocking.jpg)
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Opened up the center hole in the front rims to accept the grease cup on the front hubs, and the diesel pump bracket as well. The pump is now going in like charm. It's really awkward to rig the bracket in the mill so I skipped the mount holes. I'll customize the pump instead I think, like the standard pump.
(http://1.bp.blogspot.com/_1YSYxoIZ1Wo/S-h1kNXq3zI/AAAAAAAAAbE/qp3vECreJYk/s320/IMG_6892+copy-747833.jpg) (http://2.bp.blogspot.com/_1YSYxoIZ1Wo/S-h1lMDTNzI/AAAAAAAAAbM/vnJm7yKDGdI/s320/IMG_6899+copy-751765.jpg)
Picked up the wheels today from the sand blasting place. They will be really nice with the new paint. Pictures will come!
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Wheels are now coloured, I changed my mind and went for gray metallic instead. I'll clear coat them today. The wheel in the background is more realistic. Difficult colour to catch on a photo.
(http://1.bp.blogspot.com/_1YSYxoIZ1Wo/S-p9ugX2hnI/AAAAAAAAAbU/fh65yg5ZqnA/s320/IMG_6917+copy-710622.jpg)
Test mounted the diesel pump with the bracket. The 1Z belt wheel is spot on. I have to switch the fuel outlets though, they are longer on the Disco pump.
(http://1.bp.blogspot.com/_1YSYxoIZ1Wo/S-p9vDzo2iI/AAAAAAAAAbc/-ZUyZViw5Hs/s320/IMG_6918+copy-712210.jpg) (http://3.bp.blogspot.com/_1YSYxoIZ1Wo/S-p9vmqYgWI/AAAAAAAAAbs/PAaHNkZ8mr8/s320/IMG_6921+copy-714726.jpg)
Is this TDC on a 1Z?
(http://3.bp.blogspot.com/_1YSYxoIZ1Wo/S-p9wf0NkfI/AAAAAAAAAb8/vKRmWt113Ik/s320/IMG_6926+copy-717087.jpg)
http://switchamotor.blogspot.com/2010/05/wheel-fixin-part-ii-diesel-pump-testing.html (http://switchamotor.blogspot.com/2010/05/wheel-fixin-part-ii-diesel-pump-testing.html)
.
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Working, vacation, more working, and then a tiny spot of free time to get the engine running...
Hooked it all up and got it running today.
VW m-TDI with Landy pump (http://www.youtube.com/watch?v=Y889dPRF400#)
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Looking good.