turbo diesel into gas syncro van

[Regis]

I've just purchased an ' 86 syncro van and am about to do another conversion. I need some advice on if this will work or not.

turbo diesel from ' 84 jetta
kennedy adapter and flywheel
' 72 bus bellhousing
modify my engine support bar


My reason for not using diesel van parts is that the diesel bellhousing has the starter motor on the top of the tranny, which would interfere with the syncro fuel tank. Using the '72 bellhousing relocates the starter and also gives me way more options for starters.
Diesel syncro fuel tanks are very hard to find and expensive.

Anyone have any thoughts, thanks Aaron.

[Regis]

I might have a new plan. A friend suggested heating the fuel tank withe a heat gun and making a dent to clear the diesel starter. He has succesfully done this in the past. He is going to sell me a complete ' 82 diesel Westy with the engine in pieces for a thousand dollars. This seems to be the best route to take.

Aaron

[sven]

Not to bash your conversion ideas, but why do you want to change to an older engine?

[Regis]

My wife's jetta is soon to be scrapped and has a really clean rebuilt turbo diesel with about 5000 k on it and its running strong. The tranny is shot also.
My crappy waterboxer is giving me all sorts of trouble and I really don't like the flat 4's, and I can't afford to buy another engine anyways.

Aaron

[sven]

I see, makes sense then.
But... I know, you wrote that the starter would interfere, but why doesn't it interfere on my friends diesel Syncro?..

You don't have to burn anything out. Just clean the tank from dirt and use as is.

[Regis]

Hi sven, the reason for denting the tank is because there were no diesel syncros sold in Canada, or the States I believe. Your friend's diesel syncro would have the factory diesel tank with the proper clearance for the starter.


I was at David Marshal's (Fast Forward) to buy the diesel westy today and he gave me yet another idea. Use all of the diesel engine bits from the westy except the bellhousing. Instead, use a Kennedy adapter to lay the engine at 50 degrees and I can still use my syncro bellhousing and clutch. Then use a starter from a diesel golf mk4 with a small starter adapter that a friend of his makes (it's a piece of aluminum that goes between the starter and bellhousing). Should look like a factory diesel syncro to the untrained eye.
I am also going to use the camper interior. It even has the diesel furnace under the floor.

[andy syncro-nutz]

Why not just apply a sissor jack between the gear box and fuel tank,
Add some heat to the tank with a hot air gun,
Adjust the jack slowly as the tank heats,
Leave too cool!
Job done in an hour tops and zero cash spent,
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www.syncro-nutz.com

[Regis]

Thats a really good idea Andy. Better than heating and pushing on it with human power. But I might remove the tank to this job , after finding a small fuel leak. Can't tell if it's from the side of the tank or a hose connection. I'll be able to tell once I start removing things to do the swap. I'm sure the tank could use a good cleaning anyways.
I've checked out the Syncronutz website before. You guys do amazing work. I especially like the red panelvan.


I think I will stick to using the diesel bellhousing. This way I will only have to fabricate the exhaust system and a few brackets here and there. I also have the drivers side engine mount from a euro turbo diesel van.

[andy syncro-nutz]

No need to fabricate the exhaust if you use all the JX manifold and turbo bits! Remember to plug up the turbo return on the engine, i use peugeot sump plug's to block the aaz return hole on the block
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