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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old April 25th, 2012, 13:02   #451
rsxsr
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No fan on mine. Add to that, the L/R tire kicks crud on it too. Under normal highway conditions, I see about 30F over ambient, which I feel is reasonable. I am considering adding an aluminum shield in front of it to help protect it from road debris, but it might also improve the flow across the cooler by creating more of a low pressure area underneath the cooler.

If I really wanted to get the IAT under control, I'd use a water cooled intercooler, but that is more things to go wrong. mark
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Old April 29th, 2012, 18:56   #452
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Update

I didn't do anything over the weekend. However, early Friday morning my aluminum welder called saying he had the Intercooler ready. To my surprise, I was thinking more like a week before he could get to it. I had him to modify it so that the discharge pipe comes out on top just in front of the left rear tail light assembly. Also, I had him to change the angle of the IN pipe to better align with the discharge coming out of the Turbo. And, I had him to weld four 1/2 inch aluminum bolts on top for additional mounting points.

...............sorry no photos! I'll do those when I mount it this week!

Okay, here are four photos of my "unscientific" testing of the "snap switch" for the Intercooler Fan. As I stated in a previous post, the switch was supposed to come on at 95F and kick-off at 85F. Well, in the photos below you will see the test results. I did the test 5 times and got the same results.

In the pic below, you can see the snap switch on the left and the Electro-thermo test sensor on the right. They are mounted on a 3/32 inch thick piece of Aluminum. From the bottom, I heated it very slow with a propane torch......slow enough that the digital meter would only click up about every three or four seconds (no blow torch affect).


Below is another angle. You can see the PC cooling fan in the background. When the snap switch closed it turned on the fan. At that point I let it run until the temp dropped to the cut off point (74F).


Below you can see the temp at 100F.......when it reached 101F, the switch would snap shut and on come the fan.


Below you can see the temp at 75F.......when it dropped to 74F, the switch would snap open and the fan would stop!


As reasoned in the discussions in the previous posts, these temps are not acceptable! The kick-off temp needs to be more like 90F to 95F. The fan is just an assist. The IC is going to be located in an area that receives "ram" air while the vehicle is in motion.

I have found a better product and hope to get better results.
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Old April 29th, 2012, 19:10   #453
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I've always thought it would make sense to hard-mount the intercooler in close thermal contact with the car's body, frame rails, or sheet metal. So that, basically the IC is part of a very large heat sink and won't get very hot because it can always shed heat to a very large heat sink which itself if exchanging heat with atmosphere it moves through.

IOW: a metal-on-metal mounting via bracket and even use some thermal paste like you do when you build computers. The advantage would be it's a totally passive setup with no electrical or sensor-based failure modes.
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Old April 29th, 2012, 21:57   #454
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So Andy, when you make this trip what way do you go? Do you go up Iowa, Minnesota, then North Dakota, or do you go through the Rockies and up the West Coast of BC?
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Old April 30th, 2012, 08:05   #455
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Tom, on our first trip to Alaska (1986), I knew exactly where we would be each day and while in Alaska. I did not plan a daily itinerary for the return trip. I suppose my thinking was that we would back track. Well, just west of Watson Lake, Yukon is highway 37 (Cassiar Highway). We took it south down thru the Rockies in British Columbia.......we continued working our way south and come out at Glacier National Park, Montana.....on down to Yellowstone and finally at Dinosaur National Park in Colorado, we headed home on I-70 (28 days total). The six return trips were similar but not the same.

To answer your question, we head north on I-75 to Lexington, Ky and then west on I-64 to Louisville. From there, we take I-65 north to Indianiapolis around the loop and hit I-74 over into Illinois. At Bloomington, IL, we take I-39 straight north into Wisconsin to Portage and spend the night at a KOA (roughly a 725 mile day). From there we head west across Wisconsin on I-94 crossing Minnesota on to Fargo, ND. Then we head north to Grand Forks, ND then west on highway 2 to Minot, ND which is another 700 mile plus day. From there, we head toward Canada on highway 52 and enter at Portal/North Portal. We finish that day west of Edmonton, Alberta at nice town called Vegreville (largest Easter Egg in the world there, do a Google search)....that's another 700 mile plus day.

After knocking down over 2100 miles in three days, we slow down and take in some of the most awesome scenery one can imagine! Canada and Alaska are awesome, and so are the people!

We do plan to document the trip in a Thread, either here in the TDI club or the Samba.

Thanks for asking.............. I have Labrador on my radar too! That's another road trip, maybe summer of '13. Will I ever find time to hike the Appalachian Trail?
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Old April 30th, 2012, 09:22   #456
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I guess when you do the trip several times you can perfect your route. If you like the Appalachian Trail I recommend reading "A Walk in the Woods" by Bill Bryson. It gives a decent history of the trail and is very funny/entertaining read. I have a friend who is a priest in Kodiak, Kodiak Island, AK. He is the biggest outdoorsman I know and this is his dream job. He made the drive from St. Louis and it was over 5,000 miles, but I believe he went through Montana. I like your idea of getting to Canada in a couple days and then enjoying it from there.

Here is his route


But this is one of the pics that he had to share. I imagine you see equally as beautiful views out of the front window of your Vanagon. He drove his GMC Canyon, not the best road trip car
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Old April 30th, 2012, 10:07   #457
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Awesome map and photos! Wow!

Now, for those who read in this Thread, they can see ^^^^ why I am so anxious to head north this summer in a TDI powered VW Vanagon!

Yes, I have read Bill Bryson's book.............also, White Blaze dot com is a great web site. And, I've read numerous journals on trailjournals dot com!
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Old May 1st, 2012, 20:30   #458
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Update

Have you ever done something only to realize there was a better way or that you screwed-up? Well, I've been there and done that several times with this project.

The lastest is the Intercooler!

So, here are a few photos showing the lastest "adjustments" and "corrections" as well as the shield (duct work) to protect it from flying debris off the left rear wheel.

All comments are at the top of each photo!

In this photo you can see the shield (duct work) on the bottom of the Intercooler. Also, visible are four 1/2 inch aluminum bolts for mounting and a new location (top left) for the outlet. In order to mount the exhaust duct/shield, I had to move the outlet from the bottom to the top. The round looking cap on the side there was where the "original equipment" outlet was located.


This angle is from the other side. As part of these lastest mods, I also had the inlet pipe re-oriented so that it would better align with the outlet pipe coming off the Turbo.


This angle is a side shot


This angle shows the discharge from the duct. Also, you can see a square cap welded on the right bottom .....that's for the Temp and Pressure sensor. I need to drill a hole for mounting.


This top view shows the outlet pipe and the four bolts. Yes, they are rather long, however, I will cut them off a little. Not only will they help support the IC, I can use them to support the fan!


This pic shows the IC sitting off the duct. The area of the IC is 48 square inches and the "outlet" of the duct (small end) is only 24 square inches. I figure that at least 50% of the 48 square inches of the IC are "blocked" by the cooling tubes and fins........so, the smaller duct outlet should not block the air flow!


This is a pic of the template laying on top of the IC. It is was used for marking bolt holes and the outlet pipe hole.


Here is a straight up shot of the area behind the left rear wheel where the IC will be located. The cruddy looking "stuff" is not rust. That's the junk that the dealer sprays on as part of the prep. The rear of the vehicle is toward the bottom of the photo.


The shield/duct will be about 3 inches below the bottom of the rear quarter panel straight behind the left rear wheel. I also plan to install a shield in front of the IC and the duct from up in the fender well.

I know some of this is re-run. However, it is an important part of the project. I hope to install and seal everything in a few days.
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Old May 1st, 2012, 21:17   #459
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Quote:
Originally Posted by AndyBees View Post
Have you ever done something only to realize there was a better way or that you screwed-up? Well, I've been there and done that several times with this project.
Thats one of the main reasons I procrastinate, if I haven't done something yet I couldn't possibly have done it wrong


What don't you like about your IC set-up? Its certainly better than what I had...
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Old May 1st, 2012, 22:14   #460
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Originally Posted by jackbombay View Post
Thats one of the main reasons I procrastinate, if I haven't done something yet I couldn't possibly have done it wrong


What don't you like about your IC set-up? Its certainly better than what I had...
Well, there were primarily two things that I did not like.

1. During the initial set-up, I ignored the fact that the bottom of the IC would be blasted with road debris from the left rear wheel. So, when I began looking at installing the fan (electrical, meaning more wires), it slapped me in the face.........got to shield the IC from road debris.

2. The initial set-up did not provide the necessary "support." So, while addressing the shield idea, I realized that would be an opportunity to provide additional support!

I feel much better about it now!........ I just need to finish it~!
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Old May 6th, 2012, 08:37   #461
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Update

Here are a few pics of the "rear" OBD port. While pulling cables and wiring, I installed circuits for an OBD port at the engine bay (remember, the engine is in the rear).

This will be sort of a quick couple set-up to access the port.

Below is the connector for the OBD port usage at the engine bay in the rear of the Vanagon (for those that are not familar with the rear located engine of the Vanagon).


In this photo, besides the OBD quick couple, you can see the MAF, coolant tank and a portion of the air filter assembly.


Another angle


Another angle


I will use silicone sealer where the wires go into the back of the female connector. It will be permenantly mounted there in the rear. I guess a piece of "duct" tape can be used to cover the face. The OBD pig tail quick connector can be placed in the glove box for use as needed.
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Old May 6th, 2012, 09:26   #462
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That is really a great idea!
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Old May 8th, 2012, 20:01   #463
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Update

Over the last few days, I've continued to work on various things. I took the Intercooler back to the welder to add one more mounting tab. Also, I dropped off one of the AC line adapters to have a small brace welded on for additional support. The other adapter is much stronger by design.

Also, I finished tape wrapping the wiring up front below the dash and tucked it away. The brake and clutch switches are the next things to be addressed.

And, I need to install a new speedometer cable. As discussed in previous posts, it will be used to "spin" the modified VSS from the TDI tranny. As previously mentioned, the Digital Dakata interface will be used to convert the signal for the Speedometer and ECU.

Here are some photos of the Windshield Washer tank and pump mods to bring the system into the 21st century as well as incorporate it's function with the cluster. Comments are the top of each photo.

The TDI windshield washer pump is on the left (from a unit that does not have a rear wiper). The Vanagon pump is there in the center. The windshield washer fluid level sensor is on the right.


The pic below shows the Vanagon windshield washer pump installed in the reservoir tank. Notice on the extreme lower left bottom of the tank.....see the hole?


Here in the pic below is the TDI windshield washer pump mounted in the Vanagon windshield washer fluid reservoir. Now, there on the lower left you can see the sealing grommet for the fluid level sensor. Also, notice that I had to orient the pump pressure pipe outlet fitting to the left to provide space for the electrical connector to fit. This will not affect fitment of the tank, pipe, or operation of the pump.


Below is a view of both the pump and sensor...........Isn't it amazing how that VDO pump from an '02 Jetta will fit almost perfectly in the slot where the '84 model VDO pump fit?


One more pic
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Old May 9th, 2012, 05:58   #464
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Quote:
Originally Posted by AndyBees View Post


I will use silicone sealer where the wires go into the back of the female connector. It will be permenantly mounted there in the rear. I guess a piece of "duct" tape can be used to cover the face. The OBD pig tail quick connector can be placed in the glove box for use as needed.
Some car makers put a plastic cover over the end of the OBD port that fits rather snugly, if you found one of these it would look much nicer than duct tape and wouldn't leave residue! Some of the port covers I have seen even had a lanyard to keep it from getting lost. If I could only recall which car!
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Old May 9th, 2012, 07:40   #465
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GTiTDi, the intent of the rear OBD is to have access directly at the engine while running VCDS. I didn't want to mount the OBD port permenantly. So, I put together the disconnect and short lead. The disconnect receptacle will need the protection from the elements. I plan to keep the short lead with OBD on it in the glove box.

Here is a pic of the front OBD with the cover I think you may have in mind!


Here the cover is off
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Last edited by AndyBees; May 9th, 2012 at 07:41. Reason: Add photo
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