www.tdiclub.com

Economy - Longevity - Performance
The #1 Source of TDI Information on the Web!
Forums Articles Links Meets
Orders TDI Club Cards TDIFest 2016 Gone, but not forgotten VAG-Com List Unit Conversions TDIClub Chat Thank You




Go Back   TDIClub Forums > VW TDI Discussion Areas > TDI Conversions

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.

Reply
 
Thread Tools
Old October 10th, 2017, 17:03   #16
All Stock
Veteran Member
 
Join Date: Oct 2014
Location: Michigan
TDI(s): AHU
Default

You are going to have problems with your belt setup. I am in the process of reconfiguring mine as well.

The issue you are going to have is your tensioner is on the load side of the crank. It needs to be on the slack side. Mine exhibited the problem and it was post Water pump drive. It helped marginally for me to use a clutched alt pulley as VW originally did, but it did not solve it. The spring will eventually weaken on the tensioner and it will move due to a load situation and then tension again. It will bounce at idle due to load > slack > load > slack and on. When revved up its fine (constant higher load), but my observation was only when parked not going down the road.
I even tried flipping mine on the spring, no change.

On Edit: Duh, just noticed you mentioned you intended to lock the tensioner in place.. That will solve it. I'll leave the post intact in case someone else attempts this and needs the explanation why it wont work.
__________________
Jeep Wrangler TDI Hybrid...

Last edited by All Stock; October 10th, 2017 at 17:08.
All Stock is offline   Reply With Quote
Old October 11th, 2017, 08:03   #17
Exenos
Veteran Member
 
Join Date: Apr 2014
Location: Ontario
TDI(s): 02 Golf
Default

Yeah i had wanted to use the tensioner as a sprung tensioner but decided against it for the same reason you mentioned. Right now I made a little adjustable position lock for it and im just gonna use that to tension the belt for now. See how that goes and might just leave it if there's no problem. I have a big flywheel with almost twice the moi of the vw one so im counting on that dampening out the torque reversals to gasser levels.
Exenos is offline   Reply With Quote
Old October 11th, 2017, 09:58   #18
Exenos
Veteran Member
 
Join Date: Apr 2014
Location: Ontario
TDI(s): 02 Golf
Default

Can I block off the coolant port on the back of my head and pull the heater core coolant from the main coolant outlet? I had always assumed no but I came across a thread that leads me to believe that that only applies to alh and newer.
Exenos is offline   Reply With Quote
Old October 11th, 2017, 10:42   #19
vanbcguy
Veteran Member
 
vanbcguy's Avatar
 
Join Date: Feb 2013
Location: Vancouver, BC
Default

There shouldn't be any real problem on the AHU pulling coolant only from the front of the head. Pretty sure the side and front outlets are connected together. VW moved temperature sensors around between those two flanges over the years implying they felt they were both doing the same thing.

Some of the earlier IDI cars (which use the same basic cooling system layout but which put quite a bit more heat per hp in the cooling system) used flow control valves on the heater core feed from the side of the head that would completely block flow when the heat was off.

Sent from my LG-H873 using Tapatalk
__________________
My build thread: http://www.vwdiesel.net/forum/index.php?topic=32967.0
vanbcguy is offline   Reply With Quote
Old October 11th, 2017, 12:19   #20
oilhammer
Certified Volkswagen Nut Vendor
 
oilhammer's Avatar
 
Join Date: Dec 2001
Location: St Louis
Fuel Economy: fantastic
Default

The coolant circuit needs to remain intact, as designed. I know for sure that if you do not have the heater circuit open, the engine will overheat starting with #4 cyl, as a member here found this out on his Studebaker pickup swap.
__________________
oilhammer
www.cardocautomotive.com
oilhammer is offline   Reply With Quote
Old October 12th, 2017, 07:40   #21
Exenos
Veteran Member
 
Join Date: Apr 2014
Location: Ontario
TDI(s): 02 Golf
Default

Darn, I figured that'd be too simple.
Exenos is offline   Reply With Quote
Old October 12th, 2017, 08:20   #22
jimbote
 
jimbote's Avatar
 
Join Date: Jul 2006
Location: spiral arm, milky way (aka central NC)
Fuel Economy: golf=38-43mpg...tacoma tdi=29-33mpg
Default

you might could block off the front outlet and run an ALH flange on the end of the head... would require some die grinder work and drilling/tapping for the larger flange but i would study the coolant diagrams and be prepared to waste a head ... i remember someone posting a pic of an euro market ahu/1z style head that did NOT have a coolant outlet on the front of the head... i realize this may not address what you were trying to do... just throwing ideas out there
__________________
'You know what? This is a business.' So, now, I just keep my mouth shut and pet my chihuahuas." Mickey Rourke
jimbote is offline   Reply With Quote
Old October 16th, 2017, 09:18   #23
Exenos
Veteran Member
 
Join Date: Apr 2014
Location: Ontario
TDI(s): 02 Golf
Default

Figured I'd post the picture of the modified heater box I have, just cause everyone like pictures. Probably didn't need the silicone to seal it but I wanted a complete seal. I like my heat


My Id parts order with timing belt, exhaust studs and the other needed parts to get the engine ready to run reliably arrived to day so I just need to find someplace that stocks a 15x21mm bushing or bearing and doesn't want $25+ to ship a $5 part. I love Canada...

Last edited by Exenos; October 16th, 2017 at 09:32.
Exenos is offline   Reply With Quote
Old October 30th, 2017, 14:21   #24
Exenos
Veteran Member
 
Join Date: Apr 2014
Location: Ontario
TDI(s): 02 Golf
Default

Pilot bushing finally arrived so I buttoned up the back for the engine, adapter, spacer and flywheel all torqued and locktited. The engine is finaly ready to go in for the last time once I do the timing belt,


Also sorted out the hackery of charge piping I'm using until later. No inter cooler for version 1.0


Need to buy a crank sprocket and bolt then finish the timing belt.
Exenos is offline   Reply With Quote
Old November 3rd, 2017, 18:52   #25
Exenos
Veteran Member
 
Join Date: Apr 2014
Location: Ontario
TDI(s): 02 Golf
Default

More progress today. Made up a fan shroud/mount and throttle sensor mount. Couple other small things but those were the main items.



Don't have a better picture of the fan shroud but there's a ring of 1" 18gauge under the fan keeping it off the rad. Its a stock volvo fan from a xc70 wagon. Has a nice factory 2 speed fan controller. Same car I pulled my turbo off of actually.

The backet I made up to use the ford cable with the vw sensor. I get about 85% throttle before the carpet in the truck interferes with the pedal. I can push harder and get almost 100% travel but I think I'm going to adjust the throttle map to reflect this and put a hard stop on the pedal in the cab.


Thinking of mounting it here by the ecu but ill have to see when I get the engine back in before I make it permanent. Only thing I don't like it how close it is to the rad cap





Barring any set backs there is a chance I could have the truck driving next weekend but a more realistic time frame is 2 weeks from now. I have a few hours of finish wiring and a flange from the back of the head for the heater core to fab along with a bit of plumbing and it should be good for a test drive around the block. I'll need a bunch of fiddling for the gauges plus a few non swap related items to finish before it can be safetied and licensed.

Im currently waiting on a crank sprocket to come in at the parts store so I can finish up the timing belt then in goes the engine. I'm expecting to have it Monday.
Exenos is offline   Reply With Quote
Old November 6th, 2017, 08:24   #26
Exenos
Veteran Member
 
Join Date: Apr 2014
Location: Ontario
TDI(s): 02 Golf
Default

So how bad would it be over driving the water pump by 30% given that this is a fairly slow turning engine? I need to put the water pump on the serpentine belt right now and I have a pulley I can make work but it would result with the pump turning faster. What it means is that instead of turning 6250rpm@5k the pump would be turning 8300rpm@5k. By comparison a 1.8 has the water pump turning 8300rpm@6.6k engine rpm. I'm more concerned with the water pump speed at 3-4k because that's where the engine could potentially be sitting at while being heavily loaded. Water pump speed @4k would be something like 6.6k. Personally I'm comfortable with these numbers but I want to know what others think.
Exenos is offline   Reply With Quote
Old February 5th, 2018, 17:37   #27
Exenos
Veteran Member
 
Join Date: Apr 2014
Location: Ontario
TDI(s): 02 Golf
Default

Decided to scratch the vnt 15 and just run my td04 from the start. I was only running the vnt15 because I thought the egr port on the ahu manifold would interfere with the firewall. Decided to check and what do ya know it clears by a 1/2 inch. Td04 it is then.

Its a td04-13G from a old volvo 2.5. I had quite a bit of confusion when I measured the compressor because it measures with a 42mm inducer and 56mm exducer which lines up with a 15c not a 13g . Turns out its a volvo specific wheel. It flows 4lb/m more so I'm not complaining. Has a 7cm (0.49 A/R) housing on the exhaust so I'm a bit worried about the spool but it did come off a 2.5 and was also a stock turbo on a 2.5 diesel with the 7cm housing so I'm hoping it wont be too bad.

The td04 has a built in blow off valve it looks like. Had a single pressure reference on top of the diaphragm that I'll be feeding boost pressure for now but I might look into using it as a controlled air leak at low rpm if I actually spool fast enough to run into surge.

Sorry for the poor pics I think I had a smudge on the camera.



Exenos is offline   Reply With Quote
Old February 24th, 2018, 18:14   #28
Exenos
Veteran Member
 
Join Date: Apr 2014
Location: Ontario
TDI(s): 02 Golf
Default

Started it in the truck for the first time. The key works but I have a bad starter relay/solenoid so I had to jump the starter. Just need to buy a section of 1.25 rad hose, put the transfer case and drive shaft in and I could take it for a quick drive down the road right now but I'm going to hold off until I have a few more things done. I didn't have the oil drain done but I wanted to start it so no turbo for the video,


EDIT: How do you embed videos here?

https://www.youtube.com/watch?v=Glomf3QlVDA&

Last edited by Exenos; February 24th, 2018 at 18:16.
Exenos is offline   Reply With Quote
Old March 7th, 2018, 05:39   #29
Exenos
Veteran Member
 
Join Date: Apr 2014
Location: Ontario
TDI(s): 02 Golf
Default

Bought a new solenoid and wired up the glow plugs. Starts with the key now and embarrassingly enough it definitely starts better than my daily driver even after siting for 3 years. I might need to do valve guides and seals because its got some good blue smoke on start up and the #3 intake port had some oil in it. Hoping it cleans up when its warm because I'd like to get it on the road first.

Also made up an oil drain and relocated the waste gate.




Welded up a 90 from 2" exhaust and used an intake piece from the vw and from a volvo for the charge piping. Still need to see about putting the iat sensor in there.




The exhaust is almost done but I discoverd that the flange for the td04 is too large to fit between the trans and frame rail like the vnt15 could so I need to cut that section in two and add a joint in there.
Also waiting on a harmonic balancer to arrive since mine was absolute toast. I have today off so I'm planning on getting it to the point where I can just fill it with coolant, bleed the clutch and drive it around on the weekend.
Exenos is offline   Reply With Quote
Old March 9th, 2018, 11:05   #30
Exenos
Veteran Member
 
Join Date: Apr 2014
Location: Ontario
TDI(s): 02 Golf
Default

So I've ran into quite a snag. I pulled the chips from the ecu, read then so I could work on a tune and put them back in. Made sure the HHH and LLL were in the right sockets and now im getting a no start. Checked to make sure power is going where it should be and everything is grounded. Cranks over but not even a thought of starting. What could have I messed up with the ecu when I pulled the chips? And just in case, who's the guy on the forum who sells the rover pumps? Might go that way if I need a new ecu.

EDIT: My ecu is a 028 906 021 JB would I need to replace it with a JB version or would any 028 906 021 work?

Last edited by Exenos; March 9th, 2018 at 13:09.
Exenos is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
AHU vs ALH in a Ranger curtis75 TDI Conversions 11 February 2nd, 2017 10:26
97 Golf TDI swap Ahu scubagli TDI Cars for Sale/Wanted 14 November 13th, 2013 16:05
AHU Ranger Alchemist TDI Conversions 12 January 23rd, 2013 15:25
FS: 97' AHU Diesel Swap - 140K vwishndaetr Private TDI Items for Sale/Wanted 1 September 22nd, 2011 22:25
97 AHU TDI swap in 86 Jetta foxracer1 TDI Conversions 7 February 12th, 2010 07:14


All times are GMT -7. The time now is 23:19.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2018, Jelsoft Enterprises Ltd.
Copyright - TDIClub Online LTD - 2017
Contact Us | Privacy Statement | Forum Rules | Disclaimer
TDIClub Online Ltd (TDIClub.com) is not affiliated with the VWoA or VWAG and is supported by contributions from viewers like you.
1996 - 2017, All Rights Reserved
Page generated in 0.15514 seconds with 10 queries
[Output: 128.21 Kb. compressed to 107.16 Kb. by saving 21.05 Kb. (16.42%)]