1.9TDi AHU in T3 Van with flipped gearbox |
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scudson
Newbie Joined: 07 Nov 13 Location: Bristol Status: Offline Points: 6 |
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Posted: 30 Sep 20 at 22:55 |
Well it's been a while and I thought I would give an update on the conversion six years later. For five of those years I have been without the van here in Chile. Anyway.
Firstly the AHU had a stuck open exhaust valve in Portugal which was a bit of a bummer. RAC were awesome and repatriated the van for us using our European cover. Bonus. Fitted a AFN after that debacle. Also with synchroandy's help sorted out the fuel gauge on the Passat instrument cluster. Fabricated a scoop for the inter cooler to get the temps down. Works a charm. Designed and fabricated a swivel cooking unit. That took some work. Wood work is to my forte. Fitted a key fob for opening the doors remotely. Also fitted dead locks on all the doors after being ransacked in Barcelona. Everything that could be taken was. Luckily I still had a towel and flip flops. Then last month finally fitted a cable gear change mechanism using a Porsche Boxter module. Looks and feels the business. In neutral. In second gear. Any questions send them my way. Cheers, scott.
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busbuddy
Vanorak Joined: 22 Jul 06 Location: Leicester Status: Offline Points: 2068 |
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can the system be run without a vss, as in can the ecu be adapted to not look for a vss if the mfa etc is not going to be used bloke down the road from me has an ahu conversion that always flags up the vss is missing/implausable/etc, it dont affect the running or performance but its just starting to annoy him as we have got rid of all his other faults now
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VW Nerd
Yardie Joined: 20 Jan 08 Location: Bristol Status: Offline Points: 831 |
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Nice work. Great to here that you are up and running. This is a really interesting post with so many mods on your bus. I hope to catch you at one of the shows this year.
Tim.
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Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.
Tim Shettle www.ultimate-engineering.co.uk Bristol Tel/txt 07810 320 464 AFN TDI Panel Van |
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Kent Joker
Yardie Joined: 23 Feb 05 Location: United Kingdom Status: Offline Points: 377 |
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and a 512 very nice indeed |
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Keith
1990 PD TDI Westy Atlantic |
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SplitBusVanatic
Groupie Joined: 23 Aug 11 Status: Offline Points: 76 |
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Great conversion. Thanks for sharing.
Lovin' the Sneaky little pic of the 308 in the background. |
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GavB95
Yardie Joined: 08 Jul 13 Location: York Status: Offline Points: 673 |
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Thanks for the pics Scudson, I've fitted my AAZ/flipped box combo this weekend and I'm now working through the bay connecting everything back up.
How did you work out the point at which to cut your original gear linkage to connect the Ultimate engineering adapter? I bought my set up 2nd hand so I'm not sure if Tim gives any guidance on setting it up? Any help on that would be appreciated! Regarding PAS, you could install Corsa EPAS if you felt the need for it. http://www.super7thheaven.co.uk/blog/corsa-c-electric-power-steering-epas-a118.html |
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syncroandy
Yardie Joined: 18 May 05 Location: North Lancs. UK Status: Offline Points: 630 |
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Yes the speedo's over-read (by design) compared with the odometer. Unlike the other gauges which can be re-mapped in the eeprom, the speedo/odo related parts of the eeprom are checksummed, any modifications result in a defect being detected the odo display is replaced by 'DEF'. So I just set my VSS so the odometer is accurate, and live with the over-reading speedo.
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fufflenarnia
Vanorak #1 Cable Shift Bitch Joined: 04 Sep 10 Location: Redhill, Surrey Status: Offline Points: 1362 |
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Regarding the speedo, I read somewhere that the speedo normally overr-reads by up to 10%, something to do with German TUV regs. Apparently it is possible to adjust it slightly in vagcom, but I can't find the article at the moment....... SyncroAndy, over to you
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scudson
Newbie Joined: 07 Nov 13 Location: Bristol Status: Offline Points: 6 |
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Scimdiesel: The ECU controls the boost pressure on the KKK K14 turbo which is mounted straight on a JX exhaust manifold. We also used the Passat inlet manifold and air filter/air flow meter which was just relocated behind N/S rear light compartment. A sheet of alu keeps it from sucking hot air from the engine bay and instead make it suck cold air down the vent. Turbo is low and drainage seemed a problem when we first idled the engine. Wait and see on that one.
timmythedog: The gearbox came out of 1999 VW Passat 1.9TDI AHU 90BHP. It is slightly lower gearing than the gearbox that came with the AFN 115BHP engine. syncroandy: The speed sensor is the one in the Passat gearbox. It's wires go to the Passat dash. Question - If my true speed from GPS data is dead on what the speedo is reading, do I need to adjust it upwards to allow a small margin or will my MFA fuel economy be accurate already? DavidPallister: We had to weld the splines section from the T3 onto the Passat column right at the base. We now have a steering wheel that you adjust although I don't think it will ever get used. The reason we wanted this was to use the stalks firstly and then also have the immobiliser work as intende booted: We used Sharan discs and no we didn't need to modify anything. We also used the existing handbrake cables with a plastic pipe working as an extension of the outer casing for 10cm onto the back of the caliper. GavB95: The intercooler just fitted in the space at an angle so nicely. Will need to get into VCDS and log the IAT and see if it's doing it's job. After lots of tweaking to get the T3 alternator working and finding a few bad earths on a couple of the sensors we still need to tidy up some wires. danozeman: Power steering isn't go to happen. We would need to change the steering rack and route pipes to the front from the power steering pump in the rear which probably wouldn't fit in the engine bay.
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danozeman
Yardie Joined: 16 Feb 11 Location: Stowmarket Status: Offline Points: 548 |
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MMM. I keep reading reading these threads and makes me want a tdi.
How have you managed that column? If you could fabricate power steering in there that would be neat. |
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GavB95
Yardie Joined: 08 Jul 13 Location: York Status: Offline Points: 673 |
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Nice work mate, I really like the look of this. I'm putting a flipped box in my Bluestar using Tims old style linkage adapter, so it's good to hear it functions, even if not 100% perfectly.
Intercooler set up looks neat too, got any pics of the engine bay looking in from the top? |
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Racebiz
Groupie Joined: 29 Mar 11 Location: S E Cornwall Status: Offline Points: 95 |
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Never new such a thing existed - just ordered one. Cheers for the tip :-) |
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98 T3 PD130 Viking Top
A4 1.9 TDI Classic RangeRover 3.9 EFI |
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booted
Vanorak Joined: 13 May 07 Location: Luton Status: Offline Points: 2671 |
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good work
your rear brakes are interesting did you have to modify the disca at all? , i have a rear disc kit that i am less than impressed with .it uses mk4 golf calipers i think, dont know what discs i have and the handbrake appears to have one off cables that are seizing due to the poor deign
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DavidPallister
Yardie Joined: 03 May 08 Location: Bridgend Status: Offline Points: 446 |
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How have you joined the Passat upper column to the T3 lower column? Are the splines compatible or have you had to fabricate it?
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syncroandy
Yardie Joined: 18 May 05 Location: North Lancs. UK Status: Offline Points: 630 |
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Hi Scott, what speed sender are you using and how is the signal calibrated ?
The MFA fuel economy reading accuracy depends on this of course. |
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timmythedog
Vanorak westy fetishist Joined: 29 May 08 Location: Nr Grenoble Status: Offline Points: 3415 |
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My afn Caravelle returned 38 ave loaded up with family and trailer, and 42 empty. That was running 2900 at 70mph.
Great stuff Scudson. Do you know which model passat the gearbox came from, ie which engine it was attached to?
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Syncro doka td
T4 Multivan Generation, 151 89 Caravelle Exclusive 2.1 Caravelle GL AFN tdi 53 plate T4 Panel.888 special x factor. 88 DG Panel(uncut) calypso Atlantic pop. |
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busbuddy
Vanorak Joined: 22 Jul 06 Location: Leicester Status: Offline Points: 2068 |
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seriously ? my 1Z dragging a bungalow around on 255/55x18s has gone over 40mpg before many times thats with a 3H box and a conversion thats been in 5 years, aidan will build me a box later this year
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Scimdiesel
Yardie Joined: 19 Oct 12 Location: Milton Keynes Status: Offline Points: 496 |
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Is the turbo presure being controlled by the ecu or ,as it would on the jx. I'm impressed the ecu does not care. Is it the jx exhaust Fannie also? Which inlet, jx or ahu? The golf ahu turbo (mine) sits very low hardly any drain hight. Nice job mate. 6 months is a long project, Your mpg is envy able. My ahu with Aiden box 4.14 box is very close to but not broken the 40 mpg yet. I'm interested also in what air filter setup and how and where the airflow meter is mounted. Mines using the jx filter Behind the light and the airlfow meter inline in some flexi hose to the stock inlet piping. Nice job
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Without engineers science is just philosophy..... Joined the revolution with a 18 year old TDI :
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scudson
Newbie Joined: 07 Nov 13 Location: Bristol Status: Offline Points: 6 |
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Here's a picture of how we bolted on the Passat steering column.
Here are a couple of photos showing how we got the Passat cluster to fit. We had to cut a little out of the back of the cluster to make it fit over the master cylinder. One job that was a little bit of an arse was taking apart the sliding windows to anodise the aluminium frame black and replace the draft excluders (or whatever they are called) as they were proper scummy. When I get better photos will keep on adding to this thread. By the way I think the IAT was around 43degC.
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fufflenarnia
Vanorak #1 Cable Shift Bitch Joined: 04 Sep 10 Location: Redhill, Surrey Status: Offline Points: 1362 |
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Tim at ultimate engineering is now doing the cableshift
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