VAG 1.9 TDi into a RWD transit

[Luke]

well it's now driven as a diesel van for the 1st time in 46 years - only a few feet though

still got the noisy clutch to sort but i should be able to MOT it 1st

[Luke]

Got the exhaust done - sort of temporally, ive just put the passat back box exiting under the passengers side tbh it wasn't that noisy running with no exhaust so i dont think noise (from the exhaust) will be a problem - some bulkhead sound deadening will be added later but its not as noisy as a Di

this is how it looks - ignore the mess underneath

IMG_3549.JPG

Long term i plan to make a stainless system for it but there are pipes and tanks to add underneath (for the camper part) so i don't want the exhaust to be in the way so makes more sense to build the exhaust last

i've piped up what i think is the correct vac hoses to the actuator - i've deleted the egr so not 100% sure i've got it right without a road test but it revs up ok and without too much smoke so looks promising

really need to sort an MOT out now then take the box back off and have a look whats making the rubbing noise

[Luke]

MOT's booked for sat and it's all legal and insured

just got a few little jobs to do but so far seems to pull well

[MinorMatt]

Good luck!

[Luke]

Passed

a few little issues to sort - it won't rev up but i think its an issue with the brake pedal switch - at least i can test drive it around now

[martynx]

Passed

a few little issues to sort - it won't rev up but i think its an issue with the brake pedal switch - at least i can test drive it around now

Its common failure on the VAG's of the same vintage as your engine , the brake light even can still work but the switch gives a fault & you get engine malfunction message & bleeps etc in the dash !

[Luke]

Passed

a few little issues to sort - it won't rev up but i think its an issue with the brake pedal switch - at least i can test drive it around now

Its common failure on the VAG's of the same vintage as your engine , the brake light even can still work but the switch gives a fault & you get engine malfunction message & bleeps etc in the dash !

fingers crossed

do you know what the clutch one does is it read by the ecu

i've made a bracket to mount them against the transit pedals - just welding it up now

[martynx]

Not sure if clutch switch is crucial..I'll unplug the one on my '01 Leon TDI later & see if it does 'owt interesting; )

[Luke]

i'll have them both mounted in a bit the brake one as you say certainly makes a difference (ive tried it in my hand) - the clutch one has a vac pipe on it but it's that long since i took it off can't remember if it had anything connected

just need a break in the rain and i'll get it done

[andz327]

Have you sussed out clutch noise??

[Luke]

Not sure if clutch switch is crucial..I'll unplug the one on my '01 Leon TDI later & see if it does 'owt interesting; )

according to my drawings it's wired back to the ecu so it must read it but it doesn't seem to have the same effect as the brake one

ive got the bracket on

IMG_3564[1].JPG

but ive noticed a split in the pipe from the cam cover to the intake so i'm going to replace that incase it's an issue allowing un-metered air in

[Luke]

Have you sussed out clutch noise??

sort of
the noise has drastically reduced so much so it's hardly there now - i think it must have been something rubbing - maybe the adapter plate thats now worn off
i'm going to drive it to north weald and back and see how it is then

[andz327]

Maybe a adapter plate / belhousing bolt a hair too long catching the flywheel, or pressure plate bolts too long and catching the adapter plate

[Luke]

Maybe a adapter plate / belhousing bolt a hair too long catching the flywheel, or pressure plate bolts too long and catching the adapter plate

not sure but the flywheel and clutch are all crafter the only thing i think is different is the 1.9 crank is shorter than the 2.0 crank, which is why i had to machine the adapterplate down

[andz327]

as long as its not pressure plate to strong for the smaller engine and moving the crankshaft on its thrust washer /bearing caps (excessive end float)causing flywheel to rub somewhere