1.9TDi AHU in T3 Van with flipped gearbox and Passat Dash
Posted: 05 Jun 2014, 20:12
Well been working on my van for nearly 6 months and I am pleased to say that last week I successfully completed a 700 mile shakedown. The work involved fitting a AHU 1.9TDi engine with a flipped upside down gearbox from a 1999 Passat VW donor car using Ultimate Engineering's adaptor kit. We also fitted the steering column and dash from the Passat.
Fuel gauge isn't working hence the white one cable tied to the side of the steering column. Wiper relay from Passat is plumbed in as it compliments the wiper stalk and it's multiple intermittent settings. MFA computer also all working with outside temp and mpg etc. Managed 45mpg on open road and 41mpg doing 70-80mph on the motorway at 3000rpm, well according to the MFA we did.
Liking the blue dash, after such an effort getting it all working it's the little things that make the difference. Earthed out any warning lights that were on and just extended the relevant wires from the engine bay to have everything we could working like the speedo and rev counter etc.
Using a JX KKK turbo that was brand new and came with the van instead of the AHU one. Made up a skid plate for the lowest part of the gearbox. Made the exhaust using some tube bent correctly and a silencer box with a flexi section. The wheels are Mercedes Steel wheels 16x7J ET 37 powder coated black. Have also used a 50mm AVO lowering kit from Brickwerks.
Mounted the intercooler next to the gearbox with a bracket while still using the original cowling. No skid plate in this picture.
Found some old AP rear calipers gathering dust for the last ten years which with the Passat vented discs fitted perfectly with a new bracket.
Fitted Sharan discs to the back with Golf Mk4 calipers utilising the old handbrake cables using a bracket we made.
Some things still to do:
Sort out the fuel gauge on the dash (have sent a PM to relevant person); Try and fit the remote key fob from the Passat as I already have central locking; Fit cruise control.
The there's the insides to sort out as we have a full width rock and roll bed but sparse storage options. Need a swivel base for the drivers seat as well. Might fit some electrics and leisure battery and maybe sort out the stereo. First though was get it mechanically sound which it feels like we made a lot of progress towards now.
Sorry for the briefness. I had written this out once but a careless swipe on my keypad took me back a page and deleted my first attempt. Being adverse to writing to begin with I feel content with my concise second go.
If you have any questions fire them at me and I will endeavour to answer them.
Fuel gauge isn't working hence the white one cable tied to the side of the steering column. Wiper relay from Passat is plumbed in as it compliments the wiper stalk and it's multiple intermittent settings. MFA computer also all working with outside temp and mpg etc. Managed 45mpg on open road and 41mpg doing 70-80mph on the motorway at 3000rpm, well according to the MFA we did.
Liking the blue dash, after such an effort getting it all working it's the little things that make the difference. Earthed out any warning lights that were on and just extended the relevant wires from the engine bay to have everything we could working like the speedo and rev counter etc.
Using a JX KKK turbo that was brand new and came with the van instead of the AHU one. Made up a skid plate for the lowest part of the gearbox. Made the exhaust using some tube bent correctly and a silencer box with a flexi section. The wheels are Mercedes Steel wheels 16x7J ET 37 powder coated black. Have also used a 50mm AVO lowering kit from Brickwerks.
Mounted the intercooler next to the gearbox with a bracket while still using the original cowling. No skid plate in this picture.
Found some old AP rear calipers gathering dust for the last ten years which with the Passat vented discs fitted perfectly with a new bracket.
Fitted Sharan discs to the back with Golf Mk4 calipers utilising the old handbrake cables using a bracket we made.
Some things still to do:
Sort out the fuel gauge on the dash (have sent a PM to relevant person); Try and fit the remote key fob from the Passat as I already have central locking; Fit cruise control.
The there's the insides to sort out as we have a full width rock and roll bed but sparse storage options. Need a swivel base for the drivers seat as well. Might fit some electrics and leisure battery and maybe sort out the stereo. First though was get it mechanically sound which it feels like we made a lot of progress towards now.
Sorry for the briefness. I had written this out once but a careless swipe on my keypad took me back a page and deleted my first attempt. Being adverse to writing to begin with I feel content with my concise second go.
If you have any questions fire them at me and I will endeavour to answer them.
