VAG 1.9 TDi into a RWD transit

[Luke]

not given up on this just had a break............. nothing to do with the emissions scandal

decided to go with martynx's idea of no intercooler - i will fit one later but for now its much simpler to get it up and running intercoolerless

made this pipe for it - seems a shame that this piece will get binned when i fit the i/c

the mounting on the top i think it the air intake sensor

[vtec power gt]

Great conversion you dont need to have the intank lift pump/helper pump not all the vw models have them fitted for pd engines they are not fitted to the spanish import ones that was on information from bosch technical i had a 2001 115 bhp bora pd that had no intake pump that was remaped to 145 bhp and went fantastic and never needed it fitted to help with performance just make sure you have no restrictions in the fuel lines
If you can find the ecu version then i should still have the remap on my computer you can have if its the same version for free.

[Luke]

Great conversion you dont need to have the intank lift pump/helper pump not all the vw models have them fitted for pd engines they are not fitted to the spanish import ones that was on information from bosch technical i had a 2001 115 bhp bora pd that had no intake pump that was remaped to 145 bhp and went fantastic and never needed it fitted to help with performance just make sure you have no restrictions in the fuel lines
If you can find the ecu version then i should still have the remap on my computer you can have if its the same version for free.

thanks i did wonder if it would run ok without the in tank pump as when i ran it in the passat with the wiring loom cut back i didnt have the pump plugged in - i only noticed later

i still plan on having an ally tank made up (for the increased capacity and reliability) also i needed 2 fuel lines - i suppose the in tank pump would be usefull for priming if you ran out of diesel

[Luke]

bought a propshaft for this today - should renew my winter enthusiasm

prop is a sprinter mwb so it will need chopping down to suit the lwb mk1

[V184]

Nice work

[Luke]

had a bit of hassle with the prop - when it arrived it was the wrong one - luckily the seller was cooperative and swapped the front end for the correct one (well he thought it was the correct one) ive ended up with an automatic front end that with a bit of adaption has fitted correctly onto my gearbox - i have had to remove the extra inserts on the rubber doughnut but it all fits good
a bit more luck and the centre mount has landed 30mm off the original centre mount so next step is to make a plate that bolts to the original chassis mounts and allows the new VW/Merc center bearing to bolt up to

once i've done that i'll have to have the back half shortened - long term im thinking i may have to swapping the transit axle for one better suited to the engine gearbox ratios but i will see how it goes 1st then if i need to swap the axle i can just get another rear half prop

[Luke]

Made the prop mount today

IMG_2729.JPG

and fitted it just now

IMG_2731.JPG

so i now have a fully working front half of a propshaft

I'm thinking of swapping the back axle for a sprinter one so it matched the prop pcd and i'll get a better ratio (3.77:1) although the transit axles are strong they can get noisy - the one i have on is a 4.56:1 and i might find it too low

[1958 harry]

If you wanna sell your axle let me know. I'd be very interested in it for my Firevan.

[Luke]

If you wanna sell your axle let me know. I'd be very interested in it for my Firevan.

if you mean the original one i've already sold it, but if it's the modded mk4/5 single wheel one you'd be after then i'll let you know when i remove it

[Luke]

bit more progress today - need to get this up and running for this years show season

bought a crafter/sprinter clutch pedal complete - i thought i'd have a go at fitting it in place of the transit pedal but unfortunately the angles are all wrong the stroke of the pedal is completely different to the transit one and the slave cylinder will foul the bulkhead
so i thought it best to fit the crafter slave cylinder onto the transit pedal box after looking at it for 20 mins i finally decided to fit it vertical - it should still bleed ok this way

mocked it up today all tacked together and brought it back with me and tried it on the van - all looks good so i will fully weld it up tomorrow

pedalbox.JPG

[Lollyb]

Reading though your posts re intercoolers, some vehicles like the KIA Sedona 2007 etc models have the intercooler in the wheel well behind the stone guard then run ducting to them.

Just a thought if you're stuck for space.

[Luke]

Reading though your posts re intercoolers, some vehicles like the KIA Sedona 2007 etc models have the intercooler in the wheel well behind the stone guard then run ducting to them.

Just a thought if you're stuck for space.

i had though that and there is space there but it was the cutting through the bodywork that put me off might end up there

[Luke]

actually had it running today

few jobs to sort before i can go for a drive tho - but not long

[derv23]

[Luke]

ive finished the pedal box and fitted it back in, i ran the clutch line today - just missing 1 pipe then i can bleed it up fingers crossed it will work ok

decided to fit the original tank back in for now all im doing is fitting one of these pumps to supply the injection pump and i'll mod the sender for a return

http://www.ebay.co.uk/itm/Inline-Filter ... SwzhVWrgEr

when i have the new tank made i'll have a swirl pot fitted but for now i'll just keep it over half full