Update
Okay, other than placing the Van up on jack stands over a week ago, I've not done much until this evening. (I did do some on-line research and sent a few PMs to gurus)
So, relating to the clutch slipping issues (
EDIT: this is what's in my Vanagon>>>> 215mm clutch for a 1.6L engine) and possible use of a TDI DMF (228mm clutch), here is what I've learned.
I set out to mount a DMF on a 1.6L engine, then install a vanagon diesel bell housing, and install a vanagon diesel starter to see if all would work. The bolt pattern on the 1.6L crankshaft and bolt threads are the same for both engines. (Bolt heads are different) (for those learning, the bolt patterns on the end of the block are the same for the two engines [1974-2003 for sure])
Here is what I ran into. The Dust Cover from the Vanagon application that goes behind the flywheel (between the engine block and bellhousing) will not allow the use of the DMF.
The pics below show what I have encountered.
(comments at top of pics) (By the way, this a Turbo 1.6 engine ...future project
)
First a little history ..... notice in the pic below, you are looking at the 1.6L engine flywheel as used with the Rabbits, Jettas, etc., of the era (MK1 and probably later models). The flywheel is bolted to the pressure plate which is bolted to the crankshaft.
In the pic below, you can see the pressure plate (without clutch disc) and the center thingy functions as a throw-out bearing.
Below is a shot of the crankshaft after the pressure plate and dust cover for the Rabbit application have been removed.
Below is a pic showing the Dust Cover from a Vanagon Diesel application. The engine is laying over to the right close to a 40 degree angle (head is at about the 1:30 position)
Notice the "form" of the Dust Cover, especially around the crankshaft and downward toward the left. That part going down toward about the 7:30 position will not allow bolting-up the DMF (rubs).
The pic below shows the dust cover from the side and you can also see the DMF laying there at the end of the engine. The bolt area is recessed so much that there is no clearance due to the configration of the dust cover.
This is another shot from the side.
Below is a close-up of the dust cover from the side.
Below are a couple of pics showing the SMF
that's presently in use. As stated previously,
it is a 215mm from a 1.6L engine.
I do not have a pic of the 1.6L engine flywheel from the crankshaft side. However, I do believe it must be raised to provide adequate clearance of the dust cover.
Seems in all my research (going back two or three years), I read where someone modified the dust cover for use of a particular flywheel. However, I feel certain it was not for a DMF.
So, the question becomes, will I need to modify the dust cover if I use anything besides the OE Flywheel that come on the 1.6L engine?
Suggestions, links, ....