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T3 1.8t conversion build thread
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Originally posted by Sid1800 Sid1800 wrote:



Originally posted by fufflenarnia fufflenarnia wrote:

That's a brilliant video.

Now I am all intreagued on a 50° fitting - does it fit under the lid OK? Also, what mounts did you use?

Cheers

the 50 degree fitting will not sit under the lid you have to lift it by 6-7 inches.
the mounts have to be made up but the bars are the standard diesel ones
also you need to re make the sump.like a diesel sump.
turbo oil return has to be moved.
diesel belhousing g60 flywheel and vr6 clutch
if you are interested i do have all the bits to do the conversion again.
except for the flywheel and clutch



7 inches?

That seems like an awful lot, also taking the need to change sump, turbo oil return etc etc into account.

I keep coming back to the same example, but These guys do it at 15 degrees and raise the deck lid by an inch. Also means no messing about with sumps and oil feed returns.

Is there a reason why 50 degrees is better?

Edited by T3Panel - 08 Oct 12 at 21:18
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Originally posted by Sid1800 Sid1800 wrote:



Originally posted by fufflenarnia fufflenarnia wrote:

That's a brilliant video.

Now I am all intreagued on a 50° fitting - does it fit under the lid OK? Also, what mounts did you use?

Cheers

the 50 degree fitting will not sit under the lid you have to lift it by 6-7 inches.
the mounts have to be made up but the bars are the standard diesel ones
also you need to re make the sump.like a diesel sump.
turbo oil return has to be moved.
diesel belhousing g60 flywheel and vr6 clutch
if you are interested i do have all the bits to do the conversion again.
except for the flywheel and clutch



Thanks, that's a shame, as mine is a camper, I cannot raise the engine lid.

Still, that takes away the temptation - I just need to be happy with the agg conversion in it

Best of luck with yours, - I think it will be brilliant!
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I am about to start fitting an AFN tdi upright and hope to get it to fit under the std boot floor as the conversion will be into a camper. Time will tell if a 15 deg engine install will fit.

Tim.
Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.

Tim Shettle
www.ultimate-engineering.co.uk
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[/QUOTE]

7 inches?

That seems like an awful lot, also taking the need to change sump, turbo oil return etc etc into account.

I keep coming back to the same example, but These guys do it at 15 degrees and raise the deck lid by an inch. Also means no messing about with sumps and oil feed returns.

Is there a reason why 50 degrees is better?[/QUOTE]
 
these guys use the standard gearbox which i know will not last if you are running 200+bhp.unless you drive like an granny! I like to actually drive mineBig smile.
the golf or audi a3 sumps are flat at the bottom.
but the audi and passat 1.8t sump has a big notch in it to go over the cross member this is where i am going to fit my mounting bar so it does not sit below the sump.


Edited by Sid1800 - 09 Oct 12 at 21:27
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hello Tim
regarding the 15 degree on afn engine; should fit under the lid
may be because the inlet and exhaust manifolds sit on the left of the engine
as posing to petrol where the inlet manifold sit on the opposite side and closer to the lid at 15 degree.
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as you can see im trying to convert my t3 but i have a couple of questions if any one can help.
first of all is that im trying to line my gearbox (passat flipped).the gearbox mounting sits of set on the
2.1 t3 do i need to mount the passat gearbox the same way.
the other problem is the driveshafts do i need to put a spacer in one side as the gearbox is ofset,
or do i move the box to central and try to see if the shafts fit equal.
i have measured the shafts and both are the same length.
i know some 4 speed have different length shafts.
the 5 speed t3 box is wider than the passat.
if i centre the box might need to space both shafts equal.
like to come up with all advices then put them in a basket to come up with a final.
 
 
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Martyn (Bus boy on here) used 2 equal size adaptors on his Passat gear box which he mounted in a central position. He made his own nose cone mount to suit (so the choice of fitting holes was not relevant as he did not use a std mount here) and he also fitted his 5 cylinder Audi motor where it needed to go to keep the drive flanges on the gear box central to the std 5 speed drive shafts.

I hope this helps.

Tim.
Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.

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On my tdi conversion with Flipped Passat gearbox I used the near side set of fitting holes in the chassis cross member for the gearbox front mount.

Tim
Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.

Tim Shettle
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I'm keeping everything as central as I can.  engine (20VT) and box should be midline, gearbox mount isn't difficult to fab up, as are mounting points on the crossmember.

Got some info on driveshafts as well but not confirmed/tested yet but really want to keep with the stock T3 ones, with different inners.
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thanks for the info.
what i have come up with is that,
t3 2.1 gearbox from flange to flange is 286mm
audi gearbox 270mm
that gives me 16mm difference
so if i make 2 spacers at 8mm each put one on each end,then  line the gearbox
central.i will know the thickness of the spacers once i have got the inner cv.
as far as i know the cv should be the same thickness as the stock  ones.
 dont know why i like to keep both shafts the same size not put spacer in one side or
use two different shaft sizes.
only time will tell!


Edited by Sid1800 - 13 Oct 12 at 12:36
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another thing to take into account is that when you lower a van the distance between the flanges is shortened over a standard van. even derv and petrol gearbox flanges are in different positions but the drive shafts are the same length.so you have to take the suspension travel into account as well as gearbox position.
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as lowering vehicle mine is standard,
i have measured my driveshaft heights before stripping the van.
so when i fit my gearbox in will measure again and try to fit as close to original position plus it depends on the height of the engine,want to raise engine lid by 2 inches the max,if it comes to it.
when lowering vehicle you dont change the driveshaft so if you sit the gearbox lower it should not make a difference.
if you hold the driveshaft at horizontal and lift it,it gives you the same distance as to lowering it.
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here we have pictures of my spacers which i got a 108 driveshaft gave it to engineers and got them to cut two 8mm spacers for me.
as i was mocking the gear box to the engine notice the oil filter was fouling the gearbox.
after measuring up it was only fouling by one of the bolt holes,
which i can grind the corner of and the filter will fit.
if it was a diesel the oil filter is well bigger and a lot more problem if doing the 15 degree fitting.
 
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finally got the adaptor plate and mount from tim.
started to mock the gearbox to the right height noticed that i cant go to high
due to the drive shafts hitting the top of wishbone.
here is some of the pictures of the build.
next was to mock where the engine will sit first made the engine mounts then fitted the
engine. it sits 2 inches lower than the deck lid.could do with it sitting little higher for
ground clearance,at the moment it is sitting 5 inches of the ground.
had to lower the gearbox mount by 12mm to get the engine to sit level.
next step is to fit the drive shafts but dont know which way to go round this yet,
if any body can help all is appreciated.
 
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The petrol engine bar did not clear the Passat sump when put in line with the factory Passat rubber mounts. I guess from looking at your photos that your sump allowed space for the bar to pass behind the main pan of the sump. Are your alloy mounts from a Passat or another VW Audi car?

Looking good by the way.

I'll let you know what I do to fit my drive shafts next week.
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hi tim
the engine bar does not clear the sump if you line it up from mount to mount.
the 2 tubes that fit to the mounts are ofset to the mount bar this gives you access to the nut 
that goes underneath so you can get a socket to tighten it up.
the mounts are the standard ones from the audi a4.
went into garage today and did all the water pipes and fuel lines
just need to work out where best place to fit intercooler.
then the exhaust system.


Edited by Sid1800 - 04 Nov 12 at 18:20
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Have you looked at my intercooler scoop design posted on one of my build threads where the intercooler sits on top of the gearbox with an air scoop running down to the gearbox cross member. A low cost install that allows the use of std passat cooler.
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looked at your intercooler nice job.
still looking where to fit my intercooler,reason being is that on the diesel the intake and the turbo is on the same side where as the petrol the intake is on the opposite. dont know if longer pipes will make difference to the time it takes to boost.might still try fitting it on the side of gearbox or just above.
now i have got the van on to the floor it is sitting 5 inches from floor.
as to oil filter with the adaptor plate in cant fit oil filter on.
i might try oil filter housing from transverse engine if it clears the engine mount if not need to buy oil filter relocation kit,then i can put oil filter any where in engine bay.


Edited by Sid1800 - 06 Nov 12 at 18:37
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sorry for the delay but been busy here is a video of my 20vt caravelle for the first time start up.
just a few issues to sort out,first of all is the ecu is not sending a signal to switch the fuel pump relay on.
maybe because the immobilizer taken out of ecu has cut the supply to the relay but does start with the relay bypassed.the main issue is that the rev counter does not work,i need this to work because i am running electric power steering which needs a signal to work.if any body knows how or if any body can make me a tacho box,from the ecu i got a negative rev wire but does not work with the t3 rev counter.
other than that waiting for tim for the gear linkage to go for a test drive.
by the way thanks to tim for all the parts supplied and for all the information he has helped me on.
if any body doing diesel or petrol conversion tim is your man for all your conversion parts.
 
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Hi Sid,
 
Its nice to see you on here at last.
 
I am keen to see how the 1.8t engine and box going into your van and the TDI conversion you are doing for Chris goes?
 
I am thinking of taking out the SVX conversion you helped me with and going for one of these.
 
Are you doing both of the conversions at the same time?
 
You should stick a few pics of the TDI conversion up when your able in the Diesel upgrade forum.
 
Cheers
Al
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