Date: Mon, 01 Feb 1999 10:08:15 +0100 From: "Carlos Martmn Mayo" <emecar@rioja.ericsson.se> Organization: Ericsson Infocom Espaqa S.A. X-Mailer: Mozilla 4.04 [en] (Win95; I) MIME-Version: 1.0 Content-Transfer-Encoding: quoted-printable X-MIME-Autoconverted: from 8bit to quoted-printable by penguin.wise.edt.ericsson.se id KAA08949 Content-Type: text/plain; charset=iso-8859-1 Content-Length: 3262

Hello again, Martin.

The gas models include more equipment, but it seems easier and cheaper to make the change starting from a T3 1.6 turbodiesel.

Yes you're right!

Although it's more complex, I believe that the best option is to swap to a TDI engine. Here in Spain it's easy to get a used TDI engine, among $1300 and $2000,

That would be a very good price for a low milage engine. I've heard more like $2500 in Germany and USA.

The problem is to get a good chassis for a reasonable price. Do you know some place in Germany from where you can import a T3? Some Web page perhaps?

Many newspapers have their ads on line nowdays. Of course german newspapers will have ads in german. Best might be for you to learn how to read just enough German to understand the ads.

I have read the translation that you have made of Mart=EDn Schulte's Web page (thank you, because I don't understand neither a word of German). I understand that if the original T3 is a 1.6 TD, the following parts are only needed:

1. - Engine. 2. - Engine wiring harnesses. 3. - ECU (Engine Computer Unit). 4. - Accelerator potentiometer. 5. - Intercooler 6. - Air mass meter and if it is possible the air filter box. 7. - Catalytic converter. 8. - Left engine mount.

And optionally:

1. - TDI alternator. 2. - Oil cooler. 3. - Air-water intercooler.

Is some other thing needed?

Optionally you may want to change the gearing to take advantage of the 1.9l TD or TDI's higher torque.

Not that I can think of now.

And in the case of the Syncro model, is some other thing necessary?

Don't know, but probably not.

After reading this document, I have several doubts that I would like to clarify, if you are so kind.

a) What about the starter? Which is it mounted? That of the TDI or that of the 1.6TD?

From the 1.6TD. It mounts on the bell housing.

b) How much complicated is the TDI engine electrical wiring ?

It's a pretty clean installation at least in a Passat TDI so it should come apart easily and plug back together the same way.

Of course if it stops working at least I'd have little idea how to fix it.

c) Where is the intercooler mounted? Is it mounted the TDI intercooler or another?

You can stick a TDI or an Audi intercooler in the left (driver side) rear air intake and reroute engine air to the right. That's what I did.

d) Is there some problem with the local laws when changing motor? I think that if I don't modify the final relationship of the transmission it should not have problems, since it doesn't change the maximum speed. It only changes the acceleration.

No idea about Spain.

e) How much can you increase the power and the torque without damaging the transmission? In this case, the power would increase 110 - 70 =3D 40 hp. =A1=A1=A1 = Almost 60% !!! And the torque increases 240 - 138 =3D 102 Nm. =A1=A1=A1 42,5% more != !!

Some people with the 110Hp TDI have broken their transmission.

f) How much does the weight of the motor increase? Is it necessary to reinforce the suspension?

Not much heavier. Maybe only 10-20kg. The left rubber motor mount is a bit more squeezed on my 1.9TD. Suspension is fine.

And the brakes?

Might be good to change if you drive fast where there are hills.

g) What does it happen with the power steering?

Not many diesels have it. I don't know.

h) Which clutch is it mounted, that of the TDI or that of the 1.6 TD ? And which flywheel ?

Both from the old 1.6 TD.

i) Is it possible to install the air conditioned system of the original TDI engine ? For me it's very important, because of Spanish weather.

Probably by using B2 chassis Passat mounting brackets.

j) In the event of modifying the final relationship of the transmission, which is the advisable one?

4.57

Regarding the matter of the left engine mount, it is possible to build it oneself, or it is better to buy it. The one that sells HA PROJEKT seems a little expensive (aprox. $370). Do you know somebody that has drawings or schematics of this mount?

I do:

http://WWW.CS.Yale.EDU/users/jag/vw/engine/diesel1.9/motormount1.9l.html

And there are some other variations:

http://WWW.CS.Yale.EDU/users/jag/vw/engine/diesel1.9/motormountExpo.html

On the other hand, I have read in some place that is possible to install an intercooler on the 1.6 TD. The power increases 28% and the torque 27%. Do you know something of this topic? Is it worthwhile?

Yes it's worthwhile. You could buy a cheap intercooler at the junk yard and put it in yourself instead of paying DM 1500 to Oettinger.

The intercooler can be used either to reduce the temp load of the engine to make it last longer, or if you turn up the fueling you get more power.

Saludos, Martin

PS I've been tempted to go over to Europe, buy a Diesel camper and see all of Europe. How difficult/expensive is it for a foreigner to register and insure a VW bus/camper in Spain? -- Westy 1.9l Turbo Diesel Quantum 1.6l Turbo Diesel

Martin Jagersand email: jag@cs.yale.edu Computer Science Department jag@cs.rochester.edu Yale University

Slow down and visit the VW diesel Westy page: WWW: http://www.cs.rochester.edu/u/jag/vw -------------------------------------------------------------------