Mk1 TDI progress

[Luke]

what you need is a transit linkage it'll bot strait on the top of yours and put the stick in the right position - ive got a pic of one somewhere they are a rare piece but many people upgrade to the MT75 so there are spares about

[gilly241153]

what you need is a transit linkage it'll bot strait on the top of yours and put the stick in the right position - ive got a pic of one somewhere they are a rare piece but many people upgrade to the MT75 so there are spares about

hi so that top plate bolts strait on that would be easier for him than mt75 as they are a one piece casting he would have to re enginer the bellhousin and the prop seein his work he could make one no problem gilly

[madmark]

type 9 was only fitted to mk3 transits from 86 to 88 ,also mainly to petrol models or the lwb single wheel di ,twin wheelers mostly used the overdrive gearbox in di!

[Andrewb]

Thanks for this info , probably something I'll do when its all working, as the position is usable atm

[rottie_007]

cool conversion !!
im still debating wether to stay with teh DI in my bus, as it is only 60 odd hp wheras the van is geared for a petrol engine i think as the Di is only ticking over at 40 mph even without the OD in...

was reckoning on getting a diesel motor of 100bhp as this gives 50bhp per ton approx and nearly double the power of the DI.

I have had a passat and know how well those motors can go and they have torque too by the bucketload, am I right in thinking in respect that mine didnt have a throttle cable that the earlier pre b3 passats had a cable operated throttle on the pump??

[Andrewb]

A bit more progress...

I've now got the engine going, after deciding to abandon the electronics for now. This involved getting a mechanically operated pump from a VAG TD engine to turn mine into what people call an M-TDI. I'm planning to use all the electronics when I get time though, for higher efficeincy and power.
In the only picture I have you can see the golf radiator (with a slim electric fan benhind it) and caddy intercooler on the left. I also made up a new gearbox mount last week.
All thats left to do is adjust the pump and address some clutch issues and I should be done!

[greg123]

Interesting project.

Does the engine fit in okay without needing to mod the bulkhead, even with radiator and air con condenser? Also how do you get access to the crank bolts to do the cambelt with the crossmember that close?

Re the pump, m-tdi is fine but you may have dealt with this but a IDI pump will have the timing all wrong. A pump from a 2.8 LT or a 200tdi Land Rover will have the correct setup for a tdi motor and deliver the proper torque.

Running a 1.9tdi around 150hp with a good FMIC and state of tune on a VNT15 (or around 180hp on a VNT20 with a good intake) in a mk1 would be a fantastic combo. Cruising around I bet you'll better 40mpg at least!

Greg.

A bit more progress...

I've now got the engine going, after deciding to abandon the electronics for now. This involved getting a mechanically operated pump from a VAG TD engine to turn mine into what people call an M-TDI. I'm planning to use all the electronics when I get time though, for higher efficeincy and power.
In the only picture I have you can see the golf radiator (with a slim electric fan benhind it) and caddy intercooler on the left. I also made up a new gearbox mount last week.
All thats left to do is adjust the pump and address some clutch issues and I should be done!

[Andrewb]

Does the engine fit in okay without needing to mod the bulkhead, even with radiator and air con condenser? Also how do you get access to the crank bolts to do the cambelt with the crossmember that close?

Ye, all fits fine with no bulkhead mods and the crank bolt is easily accessible (a bit more space than I originally thought)

Re the pump, m-tdi is fine but you may have dealt with this but a IDI pump will have the timing all wrong. A pump from a 2.8 LT or a 200tdi Land Rover will have the correct setup for a tdi motor and deliver the proper torque.

I've used an AAZ pump with TDI cam plate, head and plunger and a modified control lever. Doing my finals at the moment so after that I'll time it properly with a gauge. When I left the van a few weeks ago, it had no power at all so hopefully correct timing will sort that problem.

When all the engine stuff's done, I'm going to move on to the interior; I've got some Leather Jag X-type seats and the back will be kitted out with windsurf racks and possibly a bed.

[Andrewb]

Its been quite a while since I last updated this!

Since last time I've done the following;
- Swapped my modified pump for a Landrover 200TDI pump,
- Fitted a MK3 rear axle, think it was a 4.11, so I can travel at decent speeds now
- Fitted Mk3 master cylinder and servo
- Mounted a different intercooler a bit more neatly
- New pedal bushes
- Shortened the gear lever throw by raising its pivot point - much better
- Jag X-type front seats - not actually very comfy so may change!
- Replaced rear arches, rear quarters and rear panel - just needs some finishing off atm.

To do list
- Fit my mk2 front axle with discs that I picked up yesterday - thanks Alex!
- Modify the govenor on the landrover pump for more high end power
- Fit my mk2 roof that I picked up yesterday - 1st attempt at filling the pop top hole with sheet metal wasn't great!

here are a few pics, I'll try and get some more;








Not looking forward to this bit!


Roof on my car roof!

[Andrewb]

The Mk2 front axle with discs is now in, and this weekend I started on the roof...

The old roof (pop top removed, sheet steel welded into the hole)


No roof!


New roof in place

[mk1van]

ive heard of guys wanting to use this engine in escort vans.....id say it sounded all good before you started...does it still feel that way????

great work though n hope it all works out for you... keep at it....

id be interested in this conversion also for my escort van, but not sure on what tdi one to go for.....my passat is 03 and the engine is a pain in the ass, bucket of shite and very problematic in my eyes.....my problem would be the ecu as it needs to go on a computer nearly every time something goes wrong with it .....

[Andrewb]

I'm using an AHU with a mechanically controlled pump, so no ECU to worry with.
I also have a PD engine in my passat, I don't have any trouble with it but going m-tdi with a pre PD engine as I have done with the transit is probably an easier route.