TDI diesel converstion clocks up 10,000 miles !

[HOT 1200]

Our 1987 Caravelle has just clocked up 10,000 miles since its 1.9 TDI Diesel engine conversion, so far without a single problem......
(running single wire mechanical AAZ pump)

Fingers crossed for the next 10,000 miles !!!!

Although I think the extra torque is slowly killing the 5 speed box !!!



GaV

[dennyboy70]

what exact engine did you use (ie from what car) also could you tell me what was the total cost of the conversion and what sort of performance are you geting cruising speed m.p.g

[HOT 1200]

Hi mate....
Engine Code is AHU 1.9 TDI from MK3 Golf
I purchased the van semi converted.......
(to be honest I pulled the whole lot out and started again)
Firstly, I removed and thew away the AAF code 4 speed diesel box(62mph 4000rpm) because the bus would not do more than 60mph (remember TDI's only rev to 4,000rpm)
Any faster than 50mph and it sounded like the engine was going to blow up!! It also had a nasty side out exhaust that looked horrible!!!

So Gear box out, Engine out.....started again.
I fitted a s/h petrol DW code 5 speed box and converted it for diesel use, The DW box is every bit as good as a 2.1 box but offers more flexible gears for 'round town' driving. This is because the Diff is lower geared than the 2.1 AAP box, but 5th gear is acutaly higer (.77) which gives an identical 5th gear ratio to a 2.1box but slightly lower 1,2,3,4 gears so 5th feels like a true 'over drive' perfect for low revving TDI motors!!!!

Anyway...
I then made a new exhaust, straight out the turbo, no muffler (turbo motors dont need mufflers!!!), exits just under the bumper, looks factory and sounds lovely.
The only 'clue' to an alternative engine is the Intercooler which sits just under the rear bumper and uses 'ram air' cooling from air passing under the van.

Fastest I have been is 85mph, thats was 'flat out' It wont go any faster due to the 4,000 rpm limit of the TDI motor but with a mechanical AAZ pump they actually do rev higher than when they are under electronic controll (another reason for using a mechanical pump...)but in a full height Caravelle with 3 kids, 65mph feels much safer and the TDI sounds 'asleep' in the back (3,200 rpm).....Best MPG on a steady run doing 55-60mph was 42mpg.....or you can thrash the pants of it and still get 36 minimum.......

Cost wise, Expect to pay around £400+ for a running TDI motor.....
You will need a S/H AAZ pump if you choose to go MTDI
these cost anything from £50-£100
Then you will need a new diesel clutch for a T25
(golf clutch will not fit, splines are not the same)
If you convert a petrol box like I did, you will need
Diesel bell housing from old diesel box
Diesel input shaft from old diesel box (they are shorter)
(I simply cut the petrol shaft down by 13mm but always check!)
New gaskits for the bellhousing to gearbox, always use new ones, available from VW main agent for £3.00
You must fit a spigot bearing to the flywheel, Golfs dont need them, T25's do, so just fit a new T25 diesel one.....they cost peanuts...
I would estimate a grand to do a nice conversion......I was lucky and only paid £50 for the petrol box.........
You may have to make a new engine mount (left hand side) as standard one sometimes fouls the TDI turbo...some clear, some dont.
GaV