Tdi conversion. Any tips

[Al Housman]

My latest AAZ has lasted just 2 weeks before throwing a conrod so time to look at alternatives.

Having spoken to Aidan (that guru of all things diesel!) I guess I'm looking at AHU/1Z or AFN for a simple improvement on what I've had so far.

I realise that I'll need all the electronic gizmos so a complete car is maybe the best way forward but:

what about the turbo/manifolds? Can I use the ones off my present AAZ which seem pretty good?

I'll probably reuse the clutch since it was only fitted a couple of weeks ago. I know I may have to go stronger at some point.

Will I be able to use the waterpump and alternator off the AAZ/JX?

I'll leave the gearing as it is. I need to haul logs and mountainbikers up hills so no need to cruise at 70.

I'm sure I've missed something. If anyone knows of a good site with a beginners guide to this I'd be grateful to know about it.

Thanks

Al

[discipleofsketch]

My tdi conversion uses the turbo and alternator form the donor car. The waterpump I think is compatible between several different VW td/tdi engines - mine now has an aftermarket waterpump replaced in france last year. I think it would fit an AAZ.

The sump is from a JX.

Mine also has a custom exhaust, which I would like to replace with a standard T25 td exhaust using one of these adaptors:-

http://www.ultimate-engineering.co.uk/tditurbo.html" onclick="window.open(this.href);return false;

My conversion uses an uprated/ aftermarket jx clutch kit (not sure what make). I've only done about 5000 miles on it, but no sign of slipping or wearing out yet (touch wood).

On a petrol 5-speed gearbox, it's a 60mph cruiser. I'd say it's perfectly geared for hauling logs and mountain bikers up hills though!

The other thing you'll need to think about is the intercooler. Some people run without one, mine uses a custom setup with a Citroen berlingo intercooler, which works, but has been problematic.

And you'll need to fabricate an engine mount for one side.

I know some people don't like facebook, but there's a group on there specifically for t25 tdi conversions:-

https://www.facebook.com/groups/203045493214263/" onclick="window.open(this.href);return false;

[Al Housman]

Brilliant. Thanks for the quick reply.

It looks like I'll need quite a bit off the donor vehicle. I had wondered if I could get away with a bare engine and add my AAZ bits which are essentially quite good.

I had just fitted an oil cooler to the AAZ and am in the process of trying to marry a BMW 5 series intercooler to my turbo set up so this will be ideal for a TDI. It's handy having the vents on each side of the Doka. I have fabricated a couple of scoops (quite basic) and put them over the vents to direct air to the oil cooler on one side and intercooler on the other. Didn't prevent the terminal damage that occurred but, hey, you can't have everything!

Cheers. I'll man-up and try that facebook page.

[Aidan]

Tom and Leo must be able to drive on fb

[Al Housman]

Yeah, but not sure if the old man's allowed on!!

[syncroandy]

Hi Al, you do like blowing engines up don't you ? The VW TDI motor seems to be pretty robust though so I'm sure it's a good move for you.

An AHU from a transverse-engines car is going to be your obvious choice. It should be readily available, the accessory setup is similar to the AAZ so you can mix and match parts (eg. alt.) The faffy bit with the TDI is always the turbo and intercooler ducting. To keep the TDI turbo and manifold standard you need an alternative LH mounting. I made my own but there are commercial ones. The other option is to use JX bits plus adapter plate for turbo. TDI's run quite cool as they're efficient, so oil coolers are very much optional. You will probably work it hard though so maybe its a good idea. (E D I T. so long as take-off is thermostatic obviously.)

[Aidan]

Yeah, but not sure if the old man's allowed on!!

get them on the case - they want the bikes lifting, they help find a new engine for the truck

ps drop me an email I'll send you some pics

[Al Housman]

Aye. They're as keen as I am to get the truck back in good heart.

Mind you they've quite a few mates who want to revel in the fact that I'll be borrowing a 110 landy whilst Big Green is laid up! I'm sure that's called 'Schadenfreude'!

Thanks Andy, Yes I consider myself pretty unlucky. I'm not bad on mechanics so I'm putting it down to gremlins.It really is quite a spectacular failure though and I have to chuckle a bit between bouts of despair!!

I really need to look at a conversion somebody else has done to get it clear in my mind.

I'm veering towards AHU and have put out feelers.There is a reasonable 1Z complete but no wiring etc. How easy is that to source? Could I take bits off any similar vehicle and adapt them or are they1Z specific? Could I use a turbo off(eg) a 1Z and use it on a AHU?

I'm sure I'll have plenty more questions! I hear you might be in the area this w/e so I might call by.

[syncroandy]

AHU replaced the 1Z but is essentially the same thing, just a few years younger is all. Harnesses are quite generic so long as it has the round plug for a golf type engine, however try and get a later one eg. 94 onward. The metal box ECU's are a bit better than the plastic box ones. immo can be deleted quite easily.

[discipleofsketch]

If you want to see some good examples of perfected T25 tdi installs, have a look on MV engineerings page (sorry, another facebook page!):-

https://www.facebook.com/mvengineering" onclick="window.open(this.href);return false;

[syncroandy]

AFN into T3 done right (no turbo adapter plate):

http://www.brick-yard.co.uk/forum/afn-t ... 72735.html" onclick="window.open(this.href);return false;

Bespoke LH mount on this to keep AFN turbo/manifold stock.

Another LH engine-mount example, this time a commercial one (HA projekt or similar):

http://s27.postimg.org/7yj2bsn3n/IMG_3591.jpg

The above is a customers van for which I'm doing the harness. Turbo oil drain looks like a WIP in this pic.