Turbo Diesel engine selection for 78 VW Bus

[markd89]

Hi All,

Hopefully this will be a long thread which I can add to as I put together my project.


Let me start with some background...

I'm planning to convert my 78 Bus to a TD motor. My goals are 30+ MPG, appx 90 MPH max speed, improved acceleration and engine longevity.

I will most likely get a re-geared trans so that I can cruise at 70mph at 2000-ish RPMs.

I want to go with a mechanical pump to simplify installation.

I have mechanical aptitude, but not much experience inside an engine. I'm OK to bolt things together, but I don't want to rebuild the engine myself. I'd like to get something already rebuilt. I'm in Los Angeles, CA so my last requirement is something where I can get parts somewhat easily. (i.e. I don't think I want a Europe only motor).

Questions...

1 - I found a new (not rebuilt) AAZ longblock online for $3500. This is a bare long block. I like that it's new so there should be no issues of parts quality inside, etc. Does this sound like the best engine for my application or would I be better off with a 1.6TD or ?

2 - Buying a bare long block, I run the risk of being nickled and dimed on all of the other bits - exhaust manifold, turbo, injectors, alternator, mounting pieces and of course injector pump. I've had my bus for 15 years and consider this an "investment" I'll keep forever. That said, I don't own a bank.

I'm thinking I should get a rebuilt pump, maybe with some mild power upgrades that won't effect longevity and economy. Does that make sense? Turbo I'm thinking buy new? Where to get the other bits economically?

I appreciate all help and advice!!

Mark
'78 Bus

Here's a pic of the bus. Last year I did LOTS of metal replacement, bodywork and paint :-)

[55eta]

great bus but your main problem will be cooling as they are air cooled and all the vw diesel motors are water cooled.i have only ever seen one water cooled conversion and that suffered from overheating on all but the coldest days of winter and that is in the uk not sunny California ,and the amount of work involved made it very in practicable but still not impossible P.S it would be a shame to cut up such a great bus  and it will need a great deal off cutting to fit suitable cooling system in it

[markd89]

great bus but your main problem will be cooling as they are air cooled and all the vw diesel motors are water cooled.i have only ever seen one water cooled conversion and that suffered from overheating on all but the coldest days of winter and that is in the uk not sunny California ,and the amount of work involved made it very in practicable but still not impossible P.S it would be a shame to cut up such a great bus  and it will need a great deal off cutting to fit suitable cooling system in it

Thanks for the kind words :-)

I was concerned about cooling AND cutting too. I've found others who have successfully mounted large radiators underneath the bus between the frame rails. This seems to work well and to the untrained eye, it looks stock. If I had to mount something up-front or remove the engine hatch, I probably wouldn't do it. What I have planned should work well and look stock!

Mark

[Turbinepowered]

Be careful mounting things underneath, as they'll be incredibly exposed to anything your highway driving might kick up against them. Chunks of tire or tread at 70mph can be instant death to a radiator.

[truckinwagen]

yeah, radiators are delicate beasts, I would hesitate to put it under the van.

up in the engine compartment with ducting to direct air from under the van would be my choice.

[markd89]

Yep, I thought the same on the radiators. Some people put a grille over them. Someone else claimed to have run it for 20 years without getting a hole popped in there, so I guess I'm not worried. I'll have water temp, EGT, oil temp, oil pressure gauges, so I should see if something happens...

Now, what about my engine ;-)

Mark

[truckinwagen]

if you can afford it the 1.9 will probably be your best bet.
the low end power will help get the bus moving, a K03 turbo will help to this end as well.

I would do a 1.6 with a VNT, as parts are cheaper and easier to find, but all my projects have very tight budgets.

-Owen

[Syncroincity]

The last time someone posted about doing this, at 50deg using vanagon diesel bellhousing, they found insufficient clearance between the alternator and fuel tank, IIRC. You might have to lower the engine/trans a few inches. *edit* Starter clearance... thanks, Andrew!

I'd try to find a Vanagon 5-speed trans, too.

I've seen water-cooled T-2s down in South America from the factory, with a radiator tacked right onto the front of the van. Functional, but it doesn't look right...

 http://www.volkswagen.com/br/pt/modelos/kombi.html

They're still selling them brand new in Brazil!





Maybe a parts-chasing vacation in Rio is in order?

[Otis2]

A company in the UK imports those T2 Brazilian vans, and does them up as a "Danbury" camper.

They did their best to hide the radiator behind a fake spare tire cover, which is drilled with holes for airflow.

Interesting idea, from 6' away or more.

(Check the price tag in the window... holy crap!)

[diesel smoke]

You have a beautiful bus. I'm planning on putting a 1.6TD in mine sometime soon too. I need the extra torque to push it around because of the high fiberglass top.  Mine is a '73 Safare' Custom Camper BTW.

[GEE-BEE]

Get the AAZ !

All the great peolpe will help pitch in with part's as needed...

New head assys for around 600.00

Intake 100.00

Exhaust manifold and turbo 200.00

Pump core 100.00 and then off to Giles for OHC

Fuel nozzles from Brickwerk's and fuel line's

Alternator 90 amp new 125.00, bracket 65.00

I know some people in South Africa, I brought in two complete front end clips for two caddy's

I sold one and installed the other
Where are you located ?

Gee-Bee

[bvolks73]

I'm thinking about doing a TD conversion on my 71 Doublecab at some time in the future. I've been told that the transmission will fit from early diesel Vanagons and a TD will bolt right up to it. Apparently you would need the oil pan and pickup from the diesel motor too because it sits at an angle in a Vanagon.
Or you could buy an engine adapter kit like a friend of mine. He used a 6 cylinder Subaru motor but it's roughly the same idea. His radiator is mounted underneath the frame rails and it's been going for around 3 years now. Here it is on Youtube.
http://www.youtube.com/watch?v=I_pH6vf8chA

[witoke]

I did something similar years ago with a '71, putting a Ford 2.3 liter Pinto engine in. There were a lot of problems with cooling and I finally ended up with a radiator up front. It can be done, there is a thread on here somewhere, but there is no way I'd do it to a really nice air-cooled van. You'd be better off getting a hotter air cooled motor and keeping the van relatively stock.. Plus, my experience with doing a 1.6 td transplant in a Vanagon tells me you are unlikely to get 30 mpg with an IDI in a van and no, you won't be seeing either 90 mph or 70 mph at 2000 rpm.

But hey, we all have to learn the only way we really can right? So go for it if that's what you want to do and you'll have any number of experiences to relate over beers with friends and perhaps a unique van as well.

[kane66]

I  agree with all the  haters that financially it just doesn't make sense. Personally I would love a diesel double cab. But after I had fun dreaming about it the reality sets in. For the cost I could get a nice double cab.... what ever crew cab, and use what I saved to pay for all the gas I needed. I also agree that It would be in your best interests to get a vanagon... especially of the syncro variety, do the conversion for less than it would cost and you would have something worth more than the cost. But on the other hand I understand doing something just because you want to. So if you do persue this project good luck, and make sure to document it closely for others who would like to walk the same path.