The intercoolers are sequential. See post #237 for a pic. I did two because I already had one and it was easy-ish to add the second. Also, I wasn't sure I could fit one big one in there, so yes, you're rightSorry, how are your intercoolers setup right now? Why not one big one? Space?
My setup is working nicely now. The two intercoolers were the key - one was not enough. Having the radiator up front with more flow as you suggested should be even better.damn I was kinda hoping to mimic your intercooler setup, I am committed to cutting the nose up and installing a radiator up there.. maybe it will still work, im not really wanting to interfere with clearance.
thanks for the update.
Great thread. I'm planning on putting an AHU in my 87 Syncro. On your noise & heat situ above, I installed a Dynomat hoodliner on my 02 Jetta TDI. I didn't actually install it, I just cut out the shape of the engine compartment with a little overhang at the radiator area & fenders (where the hood contacts), put some mylar packing take on the edges. I lay it on the motor - reflective side down in the winter, & backing side down spring/summer (the backing is the part you would normally peel off to stick it to the hood) It's about 1.5" thick.The last time I tried to urban camp, I couldn't get to sleep due to the large amount of heat coming up from the engine area. It took hours to cool down.
I've also been looking for a way to reduce noise. I found this site: http://lobucrod.com/index.html Their product is like the home depot foil-bubble wrap sandwich, except the bubbles are smaller and more dense.
The appeal is that the stuff is lightweight, cheap, easy to apply and should block heat and sound.
I applied two layers covering the top of the engine bay reaching to behind the rear seats.
It does seem pretty good at blocking heat. Instead of being scalding hot, the rear area is warm-hot. That's an improvement.
The jury is out on the sound reduction. At first it seemed that there was no noticeable reduction in sound. Then I piled all my junk back into the bus and it did seem more quiet than before with all of the junk and without the insulation.
I do realize there's lots of wind noise and other noise also coming from the front. This thing is never going to sound like a Lexus.
Thanks for the info.Great thread. I'm planning on putting an AHU in my 87 Syncro. On your noise & heat situ above, I installed a Dynomat hoodliner on my 02 Jetta TDI. I didn't actually install it, I just cut out the shape of the engine compartment with a little overhang at the radiator area & fenders (where the hood contacts), put some mylar packing take on the edges. I lay it on the motor - reflective side down in the winter, & backing side down spring/summer (the backing is the part you would normally peel off to stick it to the hood) It's about 1.5" thick.
Do you have a recent photo of your eng & trans hydro mounts?
Thanks, Mark. It is an idea. A few years ago, I had a spare engine that I bought from a fellow TDIClub member. It had a known history and low miles. Unfortunately with moving, moving, moving, I couldn't keep it.Mark, I would think you could find a good used long block that would get you many miles of travel. I bought a 99 Golf wrecked in the rear a few years ago for $1200. Still runs and drives nice. They probably have come down in cost since then. Look for a used car, grab what you need and sell the rest to recover some of the money spent. Sorry you wore it out.
I hadn't been suspecting the turbo. I felt it for play a few months ago and it was tight. Also, the intercoolers do not seem to be getting filled with oil.Mark, after reading this Thread and your links, I'm really surprised with these revelations about your engine.
Do you think the Turbo may be dumping oil?
Have you done a compression test?
Oil in the catch-can doesn't seem to be too bad based on your comments.
The Turbo would have been what suffered by non-spec oil, in my opinion. That's why I question as to whether or not the Turbo may be at least one of the culprits!
That is very interesting. I will shoot a picture of the oil drain today and post it. I agree that the rebuild is going to be a big project both in time and spendiness. If I can get another 60K (or 200K) miles with adding oil and doing timing belts, that would be peferred. Power is completely fine for what I need.My engine had 129k miles on it when installed in summer of 2012. I installed the Cluster from the donor. It now has 209k and "consumes" about 1/2 to 3/4 quart in 10k miles. Recent observations have led me to believe the less than correct angle of the oil drain on the Turbo may account for the majority of the oil loss (consumption). This has been debated numerous times and I just assumed mine was okay .. probably not so!
So, I'm suggesting that you consider looking at all possible probabilities that may be contributing to the oil consumption, smoke, rough idling, etc. An engine rebuild is a major undertaking. And, surely you wouldn't install that old Turbo on a very expensive rebuilt engine.
Thanks Andy!Yeah, you need to look into all those things you mentioned before making a commitment to do a rebuild.
I let my Van sit parked from late last fall until about a week ago. Although I did fire it up several times, last week when started, it smoked a lot for about 15 or 20 minutes just idling. And, for about a minute it was stumbling a bit. Now, after driving it everyday for the last 8 or 9 days, far less smoking and no rough idling when first fired up. ScanGauge says I have two bad GPs which could contribute to the smoke and some stumbling.
So, if your engine is similar to the video every time you start it, it's time to dig in and commence the process of elimination. I'd start with the GPs.
Considering you need to get those GPs out, you might ought to look at options short of pulling the head. I do believe if those GPs were replaced, the smoking might clear-up a bit and may help with the rough idling. But, you do need to see what VCDS tells you.
My bus is only smoking like that and running rough every few starts. Most starts are easy and the idle smooth like it should be.
I'll post back with what I find. If you think of more, please let me know. It's much appreciated!