Scooby - the 72 Bay thats turning 1.6 'D'

[13 window deluxe]

the golf starter isnt a direct bolt on it needs a adaptor plate will try and post some pictures this weekend of mine. the stater to solinoid wire is replaceable but it is soldered or crimped in to the brush box if i remember correctly? i had two of those wire burn out on my mk2 golf starter. did you check the glow plugs were powered up before the starter went pop i had same thing start of the week and it was glow plug fuse just happened out of the blue swapped fuse and it's been fine since the indirect injection engines are very glow plug dependent even after a short gap in running
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1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

[Bugsy_malone 666]

yeah up until it failed everything had been working fine, im thinking possible fuel blockage or water something daft like that or the engines buggered because I had been using it for several short 1/2 mile burst and it was fine, then i get in deciding it should be warm spin it over without leting the plugs warm up, then thought hmm actually i`ll let em warm up, so then i do warm them up and cant get it started no matter what I try.

I cracked injector 1 off to see what diesel was coming out and there wasnt a great deal unlike when I had been bleeding it when i first got it running, checked the fuel solinoid which is clicking if you give it a live so i dont think its that.

I have bought a mk3 tdi starter off someone on VZi, just waiting for it to arrive, if i rememeber reading somewhere the mk3 tdi starter the holes are a bit close together than the T25 (although in a straight line) and you have to slot them out, now I can see it needs a space because of the depth of the gear, the question is how thick? i did notice that the auto starter looks a bit shallower at the gear end.

Hopefully the Tdi starter might spin the engine over faster as the T25 one struggled (after all the unit had to be 25 years old!)
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Second Gear All The Way Baby!

Doing Thing Differently.

[13 window deluxe]

try this for size dude http://vwkd.co.uk/bb/viewtopic.php?p=13030#13030
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1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

[13 window deluxe]

just wrote it specially for you
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1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,

previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi

[Bugsy_malone 666]

Cool, I'm just waiting for my starter motor to arrive then I can start converting!
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Second Gear All The Way Baby!

Doing Thing Differently.

[Bugsy_malone 666]

Ok my vans been petrol for a while now, I had to convert it back to get me back to vanfest, then shortly after to pick up some bits.

However on route to vanfest I had a wee little incident happen called almost ripping off my scoop, it was a valuable lesson learned..




so with that problem also arising I have been working on a new solution thats safer for a cooling system.

I finally have the right golf (mines off a seat toledo i think) TDi starter motor like what 13 window deluxe is using for his, I have also made an adaptor plate similar..






its 12.7mm thick but I'm not 100% sure that this might be a bit thick, Hopefully this weekend I'm going to fit it up to the engine and see if I can spin it over, may need to mod it slightly and I need to trim it down but i thought I'd leave it till I'd tested it.

Now the other things I have been upto with aluminium at the moment have been 2 things.

firstly I got another 12.7mm thick piece of aluminium, I then managed to aquire an oil cooler off a volvo V40 its a heat exchanger with 2 outlets for water hose then the other side bolts to the sump, so sump side being flat I decided I needed to bolt a block of aluminium to the cooler with 2 pipe outlets. As luck would have it the outlet holes on the cooler are the right size for A/C engine oil cooler seals to fit into, so I drilled my aluminium block accordingly with a slight step the same as the A/C block and now the block needs tapping for some 6/8mm pipe fittings then all needs bolting together.
This will form my fuel heater for when I go over to using vegetable oil (at the moment its a bit of an if, veg oils cheaper than petrol) I just need to source switch over valves (seen them on ebay about £60 though!) and find a location for a 5 gallon tank for diesel.

So it'll be an Eco bus! part of the idea has stemmed from the fact that where I work in an office complex of 2 buildings, we are about to take over another building and bring more staff to the site, this means we'll have about 500 people requiring extra facilities like a gym and a restuartant. Well any sort of big kitchen for staff is going to have oil for cooking I'm sure, they'll need to dispose of the waste which is where I come in! take the oil filter it and free fuel thats the idea anyway, failing that bookers did do 20litre drums of oil and it worked out 87p a litre runing it straights good too as it requires no dangerous stuff like methanol kicking about!

Anyway..

The other major important thing I have been making from aluminium is an adaptor for the cooling system. Basically after having my rad scoop majorly damaged I anted to get my cooling system out from under the van and to another location. I really dont want to have anything on the front of my van so it pointed to the back end. Have had a fair few people say rear end cooling can be an issue, VW managed it the first time round so I was usre theres a solution.

Spending far to much time on ebay I eventuly had a eureka moment having seen a few audi and passat engines. They have a viscous fan mounted on them to draw air through the radiator and I thought just the ticket! originally I thought it was bolted to the water pump judging by the viscous mounting points being 3 screw holes like the water pump, however this isnt the case and its on its own seperate idler wheel.

So anyway I wanted to mount it on my water pump, turns out if you turn the audi fan over and mount it back on the viscous coupling when the engine in the van is running it would push air out the back of the van, perfect!!!!!

So using a 20mm thick piece of aluminium, I cut a piece out using a 79mm holesaw (biggest I had at work) which proved to be about right, I then used a combination of step drills on my pillar drill and some dremel bits to cut a 24mm one side for the viscous to locat and a 30mm hole the other side for the water pump centre to locate, I only had simple tools to do then and fitted to the water pump it looks like it has practically no detectable runout by eye, at least not enough to worry about..







so I have fitted the viscous to the water pump and it seems ok, I cant fit the fan yet because the oil filler is in the way, but the plan is that the rad should just about sit nicely behind the valance tight against the fan so the air is pushed through, that will be radiator 1 of 2. Radiator 2 will be mounted next to it and will be the inlet/exhaust side, Im going to have 2 low profile motorbike fans mounted on the back for additonal help with cooling but then underneat on the exhaust side of the engine I will make up a fibreglass panel of a fair size (might make fibreglass flat paneling for the whole underside of the van yet le manns style lol) and built a custom size Naca Duct in, the idea being the flat panel may manage to sort out some of the air underneat and scavenge some of the air skimming across the panel, this will then be ducted through the radiator to aid cooling. I'm hoping this way nothing will be lower than the engine support bar/sump and I will avoid future incidents.

Thats my plans for the minute now to get the engine running!
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Second Gear All The Way Baby!

Doing Thing Differently.

[Bugsy_malone 666]

right well I have been looking at various ways to turbo a normally aspirated as it is possible to run low boost on these things apparently, so I set about reading, I have a small turbo that runs 8-9psi boost off a 1.7 astra and I thought perfect for the job so at the weekend I was trying to have a mockup of the exhaust system along with the new fan arangement i started making above...



I have had the engine running again, not sure what was up to be honest, could have been the fuel filter head/primer, just a slow starter or anything, fitted up that fan but havent run the engine with it like that to see how much air it pushes backwards (like a forklift) and the turbo isnt pictured there as that was later.

not entirely sure the best way to use my fan yet, I have been considering building a fanshroud that pushes the airdownwards like a beetle, over a radiator so effectively the system sort of works like a normal vw one apart from sealing the fan is an issue!

Importantly its viscous so it doesnt drain huge amounts of engine power and thus keeping the diesel good on fuel.

I spent lots of saturday and sunday scratching my head over the cooling system as I want to make it more compact to avoid any misshaps and also I wanted to sort of make the engine a unit that can be taken out and run on its own with the only hose that needs connection else where being the heater matrix.


Now on to today Scouting ebay 2 days ago I found a 1600 TD from a mk2 golf 150k on the clock (low miles for a vw engine lol) and apparently it doesnt smoke, the guy decided he would sell the turbo engine alternator and starter all seperate, so i bid on the engine and turbo/manifold, so effectively its a complete engine from a mk2 golf with just the alternator missing, all for the reasonable sum of £75 the lot, seemed reasonable to me even just to use to rebuild! last engine I looked at was a 1.9td with about 130k on (obviously better) and the guy wanted £150 so i think to be honest i have done ok

After reading one of the diesel tuning forums there is a guy whos tuning 200bhp out of one of the 1600TDs!!!!! quite impressive stuff! my goal is to try and just get it to run nicely in the van, happily making up an exhaust might be easier as it can be shorted because of the turbo and also naturally quieter because the turbo doing some of the silencing.

so now I just need to ring the guy up and arrange collection, maybe for saturday afternoon as saturday morning im going to take a tow bar off a 95 passat. Free as long as i take it off for the guy its a witter towbar and doesnt look to bad to take off so I thought with the TD would be useful to adapt for my bus
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Second Gear All The Way Baby!

Doing Thing Differently.

[ruby bay]

lpg kits are supposed to be cheap horses for diesels, if you fit them yourself. the propane version will burn 100% of the fuel, most diesels only use 85% of the diesel chucked in, even the modern ones.

[Bugsy_malone 666]

well the only problem with adding propane is the fact i dont have the room for a gas bottle, I need to find some space for a small secondary fuel tank as im going to be going veg oil so I can be a bay thats diesel and smelling like a chipshop
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Second Gear All The Way Baby!

Doing Thing Differently.

[Bugsy_malone 666]

Picked it up today ..



and a turbo..



The engine itself apparently has 150k on it and it looks like thats the case, fairly black and oily through usual leaks, its pretty complect as the guy left all the hoses attached has cambelt covers etc, the only thing he took off was the alternator as he was going to sell that too and unfortunately he didnt have it with the engine today, but alas i need bigger than 45ah and one with an output for a rev counter!

The turbo has no play in it! I was impressed if its the original turbo and it has no play but spins freely which is always good!

I noticed the water pump pully is smaller on this engine to my 1600D and also the bolt mounts are closer together meaning my viscous fan adaptor wont fit (not that I think it would be that useful now, although in something like a Baja with a rad behind it it would be perfect)

so for the sake of a morning out to collect it doing a whacking 55-60mph and £75 I think today was full of win!

Now onto how im going to cool it, not entirely sure but i want to possibly steer away from my previous scoop design so I'm gonna park the van on something flat and level and get out some string and see where the lowest points are at the front and how I can make a suitable cooling system thats safe.
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Second Gear All The Way Baby!

Doing Thing Differently.

[Bugsy_malone 666]

ok past few days I been busy sorting out my van I was thinking yeah easy i'll take 4 days and do the engine swap, the weather maybe nice but i just cant work that fast!

So basically I got the TD lump and started swapping all the bits over that are needed to fit the thing at 50 degrees so i can use my T25 bellhousing and all the conversion bits I used last time.

while doing this I decided to clean it up a little, changed the front/rear crank seals and gaskets, the intermediat shaft seal and i used an a/c flywheel o'ring to replace the one on the shaft seals housing as i didnt have the right one and the old one was a bit flat! its slightly bigger diameter rubber but its the right diameter and it soon bolts down!

also changed the cambelt and tension.

I have fitted the turbo back to the engine, what a nightmare, i can only actually fit 7 out of 8 of the nuts at the moment as theres one behind the turbo somewhere that i couldnt get to, god knows how the guy got the old one off as he didnt take the turbo off the manifold!

Changed the rocker cover and noticed this baby has hydraulic tappets ooo yeah!

Fitted the JX turbo sump and oil pump I got from richiebaker at vanfest, gonna get a proper pipe outlet fot it tomorrow so i can connect my oil return.

So I has something that looks like this...



Theres no alternator yet and I have left the pulleys off the front, I managed to win a 90amp caddy alternator off a mid 90s caddy, its got a ribbed belt pulley which i thought abotu changing but then decided that it would be better to rob the alternator mount off my gti engine for my beetle (which is gonna need custom brackets anyway) and also the multi rib pulleys as the alternator brake has a spring on it for auto tension which is a dam site easier!

infact i almsot have a pair lol...


One problem I have encountered was the passenger side engine mount and the wastegate on the turbo...



basically I think I'm gonna be making up an engine mounting for that side from scratch so it clears the wastegate and my exhaust system/oil lines and still fixes in the stock mounting locations.

Something else I was also looking at while i had the engine all at the right angle was possibley fitting a small intercooler, I have one off a renault 5 which i think should be just the ticket...




now looking at it mounted somewhere there it should clear the drive shafts and its also 3-4" away from the exhaust which i would make a small stainless heatsheild, then on the front I would build a small scoop to get some air through it hopefully, at least that way it would be better than just the bit of pipe that goes from the turbo to the elbow on the inlet! The great thing about the R5 manifold is that it also has a warm up thermostat inside the thing which closes the cooler off until the air passing through it is warm enough.

Alternatively I have a 2ft square volvo intercooler but i think I may struggle to home that so easily!

So tomorrow i need to chase some parts and make up the other engine mounting and probably some of the exhaust/cooling system then back to work tuesday but alas I am close to sticking it straight back in
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Second Gear All The Way Baby!

Doing Thing Differently.