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13 window deluxe
Jedi Guardian
Joined: 22 Dec 2006
Posts: 861
Location: chesterfield derbyshire
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 Posted: Sat Feb 26, 2011 8:52 am Post subject: |
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not sure about that to be safe i'd fit the gas shortblock in then space then fit the petrol head with a 16mm plywood spacer inbetween the block and head?
_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,
previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi |
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markd89
Initiate Jedi
Joined: 24 Aug 2008
Posts: 29
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| Posted: Mon Feb 28, 2011 3:57 pm Post subject: |
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So news, my parts car is on the way to me and I'll have it in a few days!
More planning:
I probably don't care about using cruise contol. I'd also prefer not to get any CELs. Do I still need to deal with the VSS? If so, what's the easiest way to do that? Can it be de-programmed from the software or do I lose some engine efficiency or performance without it?
Thanks,
Mark |
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13 window deluxe
Jedi Guardian
Joined: 22 Dec 2006
Posts: 861
Location: chesterfield derbyshire
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| Posted: Mon Feb 28, 2011 9:00 pm Post subject: |
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| markd89 wrote: | So news, my parts car is on the way to me and I'll have it in a few days!
More planning:
I probably don't care about using cruise contol. I'd also prefer not to get any CELs. Do I still need to deal with the VSS? If so, what's the easiest way to do that? Can it be de-programmed from the software or do I lose some engine efficiency or performance without it?
Thanks,
Mark |
the ecu will throw up a code with no vss signal but if i remember correctly it doesnt limit the power or bring on the engine management light i've always fitted one to my conversions this allows cruise control to be fitted by just fitting a set of switches and loging in and changing software codes with vagcom
_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,
previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi |
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markd89
Initiate Jedi
Joined: 24 Aug 2008
Posts: 29
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| Posted: Tue Mar 01, 2011 1:45 am Post subject: |
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| 13 window deluxe wrote: |
the ecu will throw up a code with no vss signal but if i remember correctly it doesnt limit the power or bring on the engine management light i've always fitted one to my conversions this allows cruise control to be fitted by just fitting a set of switches and loging in and changing software codes with vagcom |
Did you install the donor speedo or find another solution for the VSS Signal?
Thanks,
Mark |
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13 window deluxe
Jedi Guardian
Joined: 22 Dec 2006
Posts: 861
Location: chesterfield derbyshire
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| Posted: Wed Mar 02, 2011 9:14 pm Post subject: |
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| markd89 wrote: | | 13 window deluxe wrote: |
the ecu will throw up a code with no vss signal but if i remember correctly it doesnt limit the power or bring on the engine management light i've always fitted one to my conversions this allows cruise control to be fitted by just fitting a set of switches and loging in and changing software codes with vagcom |
Did you install the donor speedo or find another solution for the VSS Signal?
Thanks,
Mark |
used a vss fitted inline in original speedo cable, i bought this from rjes as they use these on the subaru conversions
_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,
previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi |
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markd89
Initiate Jedi
Joined: 24 Aug 2008
Posts: 29
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| Posted: Fri Mar 04, 2011 5:55 am Post subject: |
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| 13 window deluxe wrote: | | used a vss fitted inline in original speedo cable, i bought this from rjes as they use these on the subaru conversions |
Very cool. I'll try running without the VSS to start with, but if I decide to go cruise control, the RJES programmable looks like the way to go.
More news/questions..
Engine mounts:
I found VW Part# 1H0 199 262L inexpensive on eb*y
and I think these look like a good solution. I'd just bolt one on each side between the support bar and the mount I get welded which attaches to the engine.
Transaxle:
I'll be using a 091 with a 4.57 differential. I wish there was a way to get a 3.x differential, but there's not, so I plan to reduce my RPMs by using lower gears for 1-4.
Ffor economy, I can up-shift at about 3000 rpm which puts me at about 2000 rpm in the next higher gear. If I want to go faster or deal with a hill, I'll just shift higher than 2000rpm.
So far, I'm thinking about a 1.14 3rd gear and a 0.70 4th gear. These seem to be the lowest ratios available and are commonly used with Vanagon TDI conversions so figure they should be close enough for my bus. I will be at approximately 2700rpm and 65 mph in 4th gear. If I come to a severe hill, then I can downshift to 3rd and go 4000 rpm and 62 mph.
For 1st, I'm thinking about 2.9 and 2nd 1.7. These are also the lowest I've found. I can run 1st gear up to 18mph at 3000rpm, then shift to 2nd and be at 1800 rpm. If I run 2nd up to 3000rpm, I'll be at 31 mph.
Here's the gearing spreadsheet I used. The yellow cells are economy driving. The orange cells are spirited driving ;-)
My engine should be about 100-110hp tuned. Do you see any issues?
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13 window deluxe
Jedi Guardian
Joined: 22 Dec 2006
Posts: 861
Location: chesterfield derbyshire
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| Posted: Fri Mar 04, 2011 8:02 pm Post subject: |
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the mounting in the photo looks like a engine mounting from a golf/bora tdi (A3) chassis i'm using the one on the other side of the subframe that mounts the gearbox as it isnt as tall on my tdi split
the 091 box in my split has a weddle 0.70 4th and it gives a great motorway cruising speed, keep a eye on rabbit boys progress when he gets his 091 box back from bears transmission an back in his van with the new 3rd and 4th gears fitted
_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,
previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi |
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markd89
Initiate Jedi
Joined: 24 Aug 2008
Posts: 29
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| Posted: Mon Mar 07, 2011 12:48 am Post subject: |
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| 13 window deluxe wrote: |
the mounting in the photo looks like a engine mounting from a golf/bora tdi (A3) chassis i'm using the one on the other side of the subframe that mounts the gearbox as it isnt as tall on my tdi split
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Interesting. I went through the ETK and the only part I could find labeled hydromount was the one I posted. I found others but they just said rubber mounting. If you happen to have a pic or a partnumber, please let me know.
If not, I'm thinking I can use the ones I found. As I'm building a custom support bar, I should just be able to design it to accommodate the tall mount. Unless I'm missing something, in which case let me know!
| 13 window deluxe wrote: |
the 091 box in my split has a weddle 0.70 4th and it gives a great motorway cruising speed, keep a eye on rabbit boys progress when he gets his 091 box back from bears transmission an back in his van with the new 3rd and 4th gears fitted |
Great! I'm thinking I should be fine with my taller 1st and 2nd gear too. I've read about people taking off in 3rd gear. If that's the case, my somewhat taller 1 and 2 should be fine! |
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markd89
Initiate Jedi
Joined: 24 Aug 2008
Posts: 29
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| Posted: Mon Mar 07, 2011 4:49 am Post subject: |
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Cooling:
I looked for a radiator which can go lengthwise under the bus and have the in and out connections at the rear. Most radiators have the in and out connections diagonal from each other.
I found these two radiators which look interesting:
http://www.kmjent.com/cart/home.php?cat=5
They claim that these will cool 500 hp. I know I'll lose efficiency because the radiator is not sitting at the front. I also know that the TDI creates less waste-heat than a comparable gasser. I'm hypothesizing these radiators should be enough.
My plan is to lay the radiator at a slight angle up to the rear so that air bubbles will rise through the hoses. It will have a temperature controlled 12" fan on top blowing down. I'll run 90 degree elbows to get the water moving towards the back of the bus rather than straight up.
The radiator will be boxed in at the sides and at the top to make a scoop effect. The total height will be about 8" which should be no lower than some of the suspension parts. I plan to run a mesh in front to keep the large detritus from getting blown in there.
I am clearly not an artist, but this should give an idea.. What do you think?
Edit: I realized I can fit two fans on top!
Last edited by markd89 on Wed Mar 09, 2011 3:47 pm; edited 1 time in total |
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13 window deluxe
Jedi Guardian
Joined: 22 Dec 2006
Posts: 861
Location: chesterfield derbyshire
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| Posted: Mon Mar 07, 2011 12:39 pm Post subject: |
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i will try and find the part number for you on the gearbox hydro mount, i dont know if you get a mid 90's tdi jetta do you in the us?
the radiator idea looks ok a large radiator is good  if you look at a diesel car the radiator is always bigger than it petrol equivalent
_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,
previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi |
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markd89
Initiate Jedi
Joined: 24 Aug 2008
Posts: 29
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| Posted: Mon Mar 07, 2011 8:47 pm Post subject: |
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| 13 window deluxe wrote: | | i will try and find the part number for you on the gearbox hydro mount, i dont know if you get a mid 90's tdi jetta do you in the us? |
We only got TDI's starting in 96. Is yours the same as the trans mount on this page? http://www.myturbodiesel.com/1000q/a3b4/mk3-jetta-passat-motor-mount-replacement.htm I'll use bigger or smaller (unless it makes a difference), but know from your previous advice that it better be hydraulic.
| 13 window deluxe wrote: |
the radiator idea looks ok a large radiator is good if you look at a diesel car the radiator is always bigger than it petrol equivalent |
The bigger of the radiators is 78cm x 33cm and the smaller 69cm x 33cm I actually didn't think those were that large, but they seem to be what would fit comfortably under there. I suppose it's all relative 
It's also interesting that you said that diesels have larger radiators than petrol. That's not what I would have expected based on the diesel making less waste heat. I'm glad you think this one will work. I realized that I can fit two fans as well, not just one, so I'll do that.
I'm thinking that I may get the smaller of the two, then if cooling is not enough I will still have enough space in front of the radiator to build a larger scoop.
Mark |
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13 window deluxe
Jedi Guardian
Joined: 22 Dec 2006
Posts: 861
Location: chesterfield derbyshire
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| Posted: Mon Mar 07, 2011 10:28 pm Post subject: |
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yes i've got the one shown as stockpassat hydro transmission mount
_________________
1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,
previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi |
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