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Engine Specific Info and Questions => IDI Engine => Topic started by: Baxter on October 05, 2006, 12:47:02 pm
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Okay, I sold my old intercooled GTD Bus and with the funds and a bit of spending money I bought a VW T3 (Vanagon) Westfalia Atlantic. I've wanted one for ages but not been able to afford one, after the sale of the Nato green GTD bus I had some money and a friend found what I wanted in Germany on E-bay, duly bit at it and won.
So, with the garage being snowed under with work I was unable to collect it so I dropped my friend off at the airport with a bag of money and off he went to Germany to bring me my winnings!
I don't think most of you will have heard of a "Atlantic" So a bit of history first..
In the UK, we didn't get Westfalia campers, all the UK ones are converted here generaly quite badly from low spec builders vans hence me wanting the right thing and having to get one from Germany, anyway... If you went to a dealer in Germany and asked for a camper you would either get the standard "Joker" model, or the slightly higher spec "Club Joker", the club joker having nicer seats, double glazing and a few other trinkets. In 1988 VW discontinued the Joker and Club Joker (But still available from other sources[wesfalia themselves?]) and replaced them with "California" and "Atlantic", the California being the lower spec one and the "Atlantic" being the higher spec on, again having nicer interior, full body kit, double glazing, digital timer for the auxilliary heating, electic mirrors etc. I think the spec is similar to the Vanagon GL camper you got, but with side planks.
Although, unlike US/Can exports we could get Turbo Diesels! Yey!
The engine is basically a 1.6TD with solid lifters and laid over at 50 degrees to fit it in the engine bay with a different LDA that lays on it's side as not to poke through the engine lid and disturb your nights sleep.
Van was a bit poorly (and slow/smokey/uneconomical) when I got it so it had a full dose of salts to bring it back to a state nearing a good state of tune, cam and pump timing set, bucket and shims adjusted etc..
So, I am running it around at the moment with the standard 70bhp lump in it while I build a AAZ which came as part payment of a job, although the engine was meant to be a runner I didn't trust it so I have pulled it in pieces to find slight damage to the nose of the crank.
Now, Im not sure how naughty this is but the damage didn't seem too bad so I have MIGged the damage up and carefully filed back the mig to close the gap up, ordered a new bolt (the original was a un modded one) and a new pulley and trial fitted it with excellent results (No movement) I do have a dead TDI outside the garage which I thought I could steal the crank from if needs be but I am confident in my crank nose repair (unless anone has any horror stories about them failling?).
I have already fitted a 25 row 235mm oil cooler up front with a thermostatically controlled take off sandwichplate in prepaeration of me meddling in the future..
The spec I am aiming for at the moment..
1.9l TD AAZ
GTD nozzles.
K14 on T3 TD exhaust manifold (I have a garret too, not too sure which to use)
Bleed valve.
AAZ injection pump, GTD pump top, governer mod, 10mm head and rotor , T3 throttle linkage.
Oil cooler (already done)
"1Y" inlet manifold. (Looks like a petrol inlet but has D shaped ports)
Charge cooler.
Water injection.
EGT, Boost, Oil pressure and Temp gauges.
Basically I can make this a more or less VW lego bolt together conversion, I have done a few standard ones for customers using the 1.6TD T3 as a base engine, I will only have to make a couple of things to make it work.
The oil feed pipe for the turbo will be made from fresh steel tube.
The oil return in the back of the block will be blocked off and the oil will drain direct to the sump a'la 1.6TD as when the engine is canted over to 50 degrees the oil doesn't like to flow up hill out of the turbo.
I am looking for a suitable charge cooler to sit behind the left hand rear light unit and I have 8" x 8" x 11" to play with, the 1Y inlet manifold will just need a 90 degree bend to go to this area.
A couple of links..
http://www.brick-yard.co.uk/VehicleSpecific/T3/info/mods/aaz.htm
http://www.brick-yard.co.uk/VehicleSpecific/T3/info/mods/diesel.htm
Piccies to follow...
Mods, please feel free to move this to another section if needs bee, I wasn't exactly sure where I should be posting it! :oops:
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Okay, first picture is a quick mock up of how things may sit.
The engine is on the stand being stripped, I just hung things off it just to get my head around how things will sit.
The inlet manifold is the "1Y" item, The exhaust manifold and turbo are the factory "JX" items as per the 1.6TD T3 in Europe.
(http://www.brick-yard.co.uk/uploads/AAZ-T3-01.jpg)
The picture below is of the port side of the manifold.
(http://www.brick-yard.co.uk/uploads/AAZ-T3-02.jpg)
The inlet tube size is quite large (70 odd mm) so I may make up another piece to bolt on to reduce the diameter to keep it inline with the charge cooler plumbing.
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Mmm, that manifold saves a lot of re-working of the 1.6 item, and a lot JB Weld too... :)
Gonna be both the best diesel camper in the UK and a real flyer too then - water injection?
http://www.aquamist.co.uk/dc/dc.html Aquamist did the recent JCB world record breaking diesel car's water injection and they have a pump just waiting for you !
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Use the all aluminum (so it doesn't pop when you up the boost) Saab 900 intercooler (charge cooler?).
Andrew
Sorry, Heh, I've had this discussion with Harry Mann!
In the UK, for some reason we call a air to water intercooler a charge cooler, a air to air intercooler is a a plain old intercooler.
Is the Saab item a air to air or air to water cooler?
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Saab unit is air-to-air.
Double glazed windows? Are you serious? All of them?
Pics, please. I'm having trouble imagining that.
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Wow that intake manifold is ten thousand times better than any of the vw turbo diesel manifolds we got on this side of the pond.
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Hey Dave,
First of all thanks for the clutch, looks awesome and was packed really well, and second could you get some of those 1Y intake manifolds?
Peter
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Hey Dave,
First of all thanks for the clutch, looks awesome and was packed really well, and second could you get some of those 1Y intake manifolds?
Peter
There is a VW scrap yard down the bottom of the road, thats where I picked mine up, when Im down next I will grab a batch if there are any, not something that really sells as, well, they never go wrong!
There are some different ones, with EGR etc, I'll see whats avaailable.
Pictures?
http://www.brick-yard.co.uk/forum/forum_posts.asp?TID=8583&PN=2
(http://www.brick-yard.co.uk/forum/uploads/images/Baxter/2006-07-28_203459_Atlantic_005.jpg)
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Okay, just been outside with the camera for a few piccies...
Fuel filler fitted.
(http://www.brick-yard.co.uk/forum/uploads/images/Baxter/2006-10-07_173444_filler.jpg)
Beauty rings fitted to speedo and rev counter, note Diesel revcounter!
(http://www.brick-yard.co.uk/forum/uploads/images/Baxter/2006-10-07_173525_rings.jpg)
Starting point of engine conversion, a bog standard 1.6TD, note the oil cooler sandwich plate and assoc. pipework.
(http://www.brick-yard.co.uk/forum/uploads/images/Baxter/2006-10-07_173637_engine.jpg)
Oil cooler take off plate fitted.
(http://www.brick-yard.co.uk/forum/uploads/images/Baxter/2006-10-07_173852_takeoffplate.jpg)
Air filter airbox (You will see why I posted this in a few months when I have the AAZ running!)
(http://www.brick-yard.co.uk/forum/uploads/images/Baxter/2006-10-07_174013_airbox.jpg)
A couple of pictures of the double glazing someone asked for.. Only the rear windows are double glazed, the cab glass is green tinted, the left hand middle window is a bottom opener as it were, there are sliding ones out there, quite rare though.
#1
(http://www.brick-yard.co.uk/forum/uploads/images/Baxter/2006-10-07_173739_window01.jpg)
#2
(http://www.brick-yard.co.uk/forum/uploads/images/Baxter/2006-10-07_173756_window02.jpg)
Nasty OEM "ATLANTIC" sticker on front panel.
(http://www.brick-yard.co.uk/forum/uploads/images/Baxter/2006-10-07_174125_sticker.jpg)
Westy roof without luggage rack, suitable for campers with sunroofs!
(http://www.brick-yard.co.uk/forum/uploads/images/Baxter/2006-10-07_174218_roof.jpg)
[/img]
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... and its incredibly quiet with all that soundproofing around the engine - at the moment, eh?
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Yeah, really quiet, Im not sure how and whybut it seems that the Atlantic does come with more sound deadening that other T3's.
It also has the extra cover over the exhaust box that is also insulated.
As fas as I am lead to believe there were 950 atlantics made, 500 of them pop tops so they ain't exactly thick on the ground, only available in 3 colours, Alpine white, Calypso green and a Kirsch red.
More info on Atlantic and California models here.
http://www.brick-yard.co.uk/forum/forum_posts.asp?TID=8537&KW=atlantic
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Wow that intake manifold is ten thousand times better than any of the vw turbo diesel manifolds we got on this side of the pond.
The manifold is from the non turbo version of the AAZ, It's like a AAZ, but just non turbo, it was fitted to the Seat based Caddy, MKIII Golf 1.9D and a few other things, after that was the SDI, which again is the direct injection non turbo Diesel engine, this was also 1.9l.
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Okay, it's been a while but I am getting there, honest!
Had this engine kicking about for a bit, just never seem to get the time to fettle it, but it's almost ready to drop in now so I thought I would share some pictures of it.
Spec.
Bog standard Vege 1.9TD "AAZ"
Specially built hybrid turbo with larger compressor.
"1X" (1.9D from T4) inlet manifold with breather removed and custom plug fabricated to act as feed for LDA.
Custom inlet manifold adapter in 2 1/4" to suit charge cooler piping, hopefully left enough room for possible water injection in the future.
Pace single core charge cooler.
Exhaust manifold refaced and fitted with EGT probe.
Rover boost pin for the LDA.
Stainless steel 2 1/2" straight though exhaust system with adjustable dangle angle tail pipe (later '89 on style - larger box, hopefully quieter!). - available to buy soon!
TDI flywheel, lightened and clearanced to suit JX *** cover.
TDI clutch and input shaft.
Turbosmart boost controller
New Meyle oil pump, sump painted black to help with cooling.
Mocal thermostatic oil cooler take off with 25 row Setrab oil cooler.
VDO oil pressure, oil temp, boost and EGT gauges to fit (Wiring run)
Brickwerks throttle lever kit, oil return line kit, block bung etc.
Lots of silicone hoses!
K&N Apollo air box.
New Meyle engine mounts.
All new water housings ans genuine sender units.
This will be coupled to a rebuilt AAR gearbox, which is a AAP gearbox but with a Limited Slip Diff, Diff is currently in pieces being rebuilt.
Lots of new bearings to fit to the gearbox! oh, and a few synchros too!
German Ambulance (Krankenwagen) genuine VW brand new trailing arms to fit (these have anti roll bar brakets fitted!)
Genuine VW rear antirollbar kit to fit, Brackets are the only bits I cannot find a part number for so my machine shop is making some to weld to the chassis legs.
I'm looking for a reliable 100bhp, a bit more torque and some decent mpg and the most of all, be able to climb hills with the family aboard!
Pictures.
(http://www.brick-yard.co.uk/forum/uploads/5/01.jpg)
(http://www.brick-yard.co.uk/forum/uploads/5/02.jpg)
(http://www.brick-yard.co.uk/forum/uploads/5/03.jpg)
(http://www.brick-yard.co.uk/forum/uploads/5/04.jpg)
(http://www.brick-yard.co.uk/forum/uploads/5/05.jpg)
(http://www.brick-yard.co.uk/forum/uploads/5/06.jpg)
(http://www.brick-yard.co.uk/forum/uploads/5/07.jpg)
(http://www.brick-yard.co.uk/forum/uploads/5/08.jpg)
(http://www.brick-yard.co.uk/forum/uploads/5/09.jpg)
(http://www.brick-yard.co.uk/forum/uploads/5/10.jpg)
(http://www.brick-yard.co.uk/forum/uploads/5/11.jpg)
(http://www.brick-yard.co.uk/forum/uploads/5/12.jpg)
(http://www.brick-yard.co.uk/forum/uploads/5/13.jpg)
(http://www.brick-yard.co.uk/forum/uploads/5/14.jpg)
It's a bit dusty, should have given it a clean and taken pictures nearer the door I think!
:)
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First off let me drool er I mean comment on your engine, yummy.
Second, you should be gathering up those intake and exhaust manifolds and selling them to us over here..
We would love to have those available to us..
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Keep the great pictures and stories coming as you work thru it !!
That exhaust makes me think of my first Beetle ! :cry:
Vince
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First off let me drool er I mean comment on your engine, yummy.
Second, you should be gathering up those intake and exhaust manifolds and selling them to us over here..
We would love to have those available to us..
Dan took all the words right out of my mouth!
WoW!!
and i agree!
we need some of those!
Duane
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I think you have more money in that S.S. muffler than the motor !!! LOL !! Very nice looking !!! When are you going to drive it ?
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The muffler is a new product I am going to be selling, this was the trial one.
They ain't that expensive and guaranteed for life, plus no one on the aftermarket seems to do the later style box like that and they are obsolete from VW...
The motor came in part of a deal, basically a customer bought it for an engine conversion and when the van arrived it wasn't the pretiest and didn't deserve a freshly rebuilt motor, so we stuck him a 1.6NA back in and did a load of other work and we took the engine as payment for the job as he couldn't sell it back on again.
Customer happy he shifted the engine and got his van back on the road without spending any more money and I got a brand new lump at sensible money leaving me a bit spare to pay for the other nice bits it's got.
When am I gunna drive it?
hhmm.
I run the workshop and I fix these things daily so enthusiasm for working on my own isn't as high as it could be!
Europes biggest VW Van show (www.vanfest.org) is in a few weeks, ideally I would like the engine in for then but the workshop is uber busy (booked till Nov at the moment (10 weeks!) and I can't see me having the time to finish it, now this is going to sound lame but I may get someone in to do it for me as I simply don't have the time!
The parts for the ZF LSD are obsolete from VW, so I have managed to get through to the only bloke in the UK that works for ZF that seems to know what one is and he has sent me a manual for it as well as a parts list so I am hopefully going to rebuilt very soon so I can get the transaxle rebuilt and put the whole shebang put in as one lump.
:)
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No probs at all here with it being a left hooker, I run a garage with traders insurance so it doesn't even load up my insurance.
:)
Theres loads of left hookers in the country, even some Vanagons but most come in from Europe as mine did.
I think some European countries are a little bit funny about going the other way, I have a customer who is having all sorts of nightmares trying to import a camperised right hand drive syncro panel van into Spain.
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What a spec...! Be interested to see how that turbo works out Simon...
New Meyle engine mounts.
You mean new Diesel mounts? Think I need some badly!
Just done over 2,000 miles RHD in France, Andorra and Spain, no big problem from a driving perspective anyway.
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I can get them Clive, not a problem.
These were the trial set, I hate buying a load of stuff in and finding out it's crap, so I'll buy one set in and see, TBH I think they are OEM, they are the best aftermarket ones I have seen and the best price too.
I've been meaning to get some in anyway, that was the kick I needed to remember!
:)
Thats the thing I am finding out at the moment as most of the stuff I'm selling I'm sure comes out of one factory and loads of others brand them up as their own.
I have a lot of Febi stuff which has VW numbers ground off making me think that a lot of it is OEM.
Febi and Meyle are well known re-boxers, but thats a not a problem when the quality is there.
If they were *** or I had any doubt about them I wouldn't sell them.
I have a friend who sells car parts for a living, he thinks I am daft sometimes as I want to sell the right kind of stuff thats going to last as long as the OEM stuff does, he thinks I should buy cheaper stuff, sell it on at a similar price and replace it more often getting repeat custom.
He's begining to realise I'm not like that now!
:)
My next thing to move into once I've got all this Elring/KS stuff set up is cables and good quality sender units for temp etc...
Got a load of german stuff on order, just awaiting it landing.
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We shall have to compare notes soon then... but need some diesel mounts asap.
Lots of peeps will need those gauges that don't have them, mine were a godsend on recent trip, esp. when i/c pipes jumped off a couple of times... wanting an inlet temp gauge now :wink:
Engine ran well to Andorra and back (25mpg overall, 29mpg max), but needs bigger intercooler radiator area up front so anyone know of a reliable good, water pump for such a system that doesn't cost £90 (all the £60 and £90's add up) - bought another £50's worth of i/c hose reducers from SFS today, can't go on like this... :)
I have a kangarooing/bucking problem at a fixed throttle opening at 2150 rpm to 2250 rpm, which goes away with a change in throttle setting but can be 'very' annoying, worse in top gear - any ideas? Water/air in injection pump possible??
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The oettinger set up uses what looks like an auxilliary water pump from a JX.
I have a Pace products brushless thing, came with the cooler.
I was thinking of using a T3 heater matrix as the radiator for my set up.
What sort of tempss are we expecting?
what about having another sender unit in the turbo pipe and a switch on your oil temp gauge? flick between the 2 then.
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I was thinking of using a T3 heater matrix as the radiator for my set up.
Thinking bigger at front of course
What sort of temps are we expecting?
200C Max ? Hopefully a lot less :)
what about having another sender unit in the turbo pipe and a switch on your oil temp gauge? flick between the 2 then.
That'd work, but how much are the senders.. I've got a CHT sender and gauge that's waiting to go on soon.
You are right to go 25 row oil cooler, my 19 row can be pushed to 120C maybe more, but that's hot and long climb. Without it, it'd be there in a minute or two and then climb straight on to beyond 130, so 25 rows and big pipes or hoses to the front for the oil cooler seem to give just a minute or so buffering effect, not much more :shock: But still worth having :)
The amount of air these things use is frightening, and that air pickup and filter needs to be sure of handling it. I changed (JX) filters once and blew one out twice. Pete's bulldozer sized one in the locker and getting air from the rear cab vents fared much better. But that was very dusty in the hills, layered the whole vehicle and got in every unsealed area...
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I will then, ta!