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1.9TDi AHU in T3 Van with flipped gearbox

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scudson View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote scudson Quote  Post ReplyReply Direct Link To This Post Topic: 1.9TDi AHU in T3 Van with flipped gearbox
    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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Post Options Post Options   Thanks (0) Thanks(0)   Quote busbuddy Quote  Post ReplyReply Direct Link To This Post Posted: 12 Jun 14 at 11:32
Originally posted by syncroandy syncroandy wrote:

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.

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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Post Options Post Options   Thanks (0) Thanks(0)   Quote VW Nerd Quote  Post ReplyReply Direct Link To This Post Posted: 12 Jun 14 at 09:25
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.
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote Kent Joker Quote  Post ReplyReply Direct Link To This Post Posted: 11 Jun 14 at 15:23
Originally posted by SplitBusVanatic SplitBusVanatic wrote:

Great conversion. Thanks for sharing.
Lovin' the Sneaky little pic of the 308 in the background.




and a 512 very nice indeed
Keith

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Post Options Post Options   Thanks (0) Thanks(0)   Quote SplitBusVanatic Quote  Post ReplyReply Direct Link To This Post Posted: 11 Jun 14 at 12:55
Great conversion. Thanks for sharing.
Lovin' the Sneaky little pic of the 308 in the background.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote GavB95 Quote  Post ReplyReply Direct Link To This Post Posted: 11 Jun 14 at 11:27
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! Thumbs Up

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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Post Options Post Options   Thanks (0) Thanks(0)   Quote syncroandy Quote  Post ReplyReply Direct Link To This Post Posted: 11 Jun 14 at 07:45
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote fufflenarnia Quote  Post ReplyReply Direct Link To This Post Posted: 11 Jun 14 at 06:11
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote scudson Quote  Post ReplyReply Direct Link To This Post Posted: 10 Jun 14 at 23:35
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote danozeman Quote  Post ReplyReply Direct Link To This Post Posted: 09 Jun 14 at 17:17
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote GavB95 Quote  Post ReplyReply Direct Link To This Post Posted: 08 Jun 14 at 17:56
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote Racebiz Quote  Post ReplyReply Direct Link To This Post Posted: 06 Jun 14 at 20:55
Originally posted by fufflenarnia fufflenarnia wrote:

That's brill.

I've been using a cheap blue tooth obd socket off ebay (£5) and torque from Google play, it shows lots of good data on your phone or including intake temps.


Never new such a thing existed - just ordered one. Cheers for the tip :-)
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Post Options Post Options   Thanks (0) Thanks(0)   Quote booted Quote  Post ReplyReply Direct Link To This Post Posted: 06 Jun 14 at 16:35
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote DavidPallister Quote  Post ReplyReply Direct Link To This Post Posted: 06 Jun 14 at 10:56
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote syncroandy Quote  Post ReplyReply Direct Link To This Post Posted: 06 Jun 14 at 09:04
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote timmythedog Quote  Post ReplyReply Direct Link To This Post Posted: 06 Jun 14 at 08:00
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote busbuddy Quote  Post ReplyReply Direct Link To This Post Posted: 05 Jun 14 at 23:24
Originally posted by Scimdiesel Scimdiesel wrote:

Your mpg is envy able.     My ahu with Aiden box 4.14 box is very close to but not broken the 40 mpg yet.     


seriously ?

my 1Z dragging a bungalow around on 255/55x18s has gone over 40mpg before many times Confused

 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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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scimdiesel Quote  Post ReplyReply Direct Link To This Post Posted: 05 Jun 14 at 23:06
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote scudson Quote  Post ReplyReply Direct Link To This Post Posted: 05 Jun 14 at 22:52
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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Post Options Post Options   Thanks (0) Thanks(0)   Quote fufflenarnia Quote  Post ReplyReply Direct Link To This Post Posted: 05 Jun 14 at 22:34
Tim at ultimate engineering is now doing the cableshift
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