'99 Eurovan TDI conversion & manual trans conversion

Today was one of those days in TDI conversion land where things just go together superbly and at every turn we're celebrating with high fives.  Don't get too excited though: these were all small victories that, viewed in the context of the whole conversion are just minor events.  Still, they do excite us--especially when we we feel like we are correcting some of VWs less appealing conventions (like a fuel filter mounted under the vehicle).  And when we successfully achieve one of these "corrections" with factory-esque grace, we gladly extend high fives all the way around.

Fuel System:

TDI fuel filter installed in TDI fuel filter bracket just aft the upper radiator core support.  Simple, elegant, easy to R&R, no crawling under the van.  Filter perfection in my book.

A clear fuel supply line is always used in our conversions sticking with the factory convention and a logical diesel mechanic's common sense: Having a visual on fuel supply can be very helpful diagnostically at times.

And back at the tank where the gas filter use to be.  No hose was cut or tweaked with here, just a simple VW TDI spec one-way valve installed to join the two fuel hoses (former in/out of the gas fuel filter) together, completing the circuit from tank to fuel filter to injection pump.

Tank re-installed with diesel/TDI mods complete.


















Air intake system in repose:

 Air intake system complete.  It looks so simple in this picture, but what remains unshown is the mating of two VW intake pipes to get the length, end sizes and flexiblity we needed for this short jog from air box/MAF to turbo intake pipe.  Intercooler plumbing/install on deck for tomorrow.

'99 Eurovan TDI conversion & manual trans conversion

Our attention today was split between finalizing the power steering system, finishing the 5-spd conversion by installing the clutch hydraulics, and starting to hook up the coolant system.  Fuel system and coolant system on tap for tomorrow and then it's time to fill with fluids!

Interfacing VR6 power steering with TDI AHU engine:

 Power steering pump installed and high and low pressure lines hooked up.

Another angle of the PS setup.  Low press line comes in on a long sweep up to the PS reservoir.  High press line attaches via banjo bolt.

Accessory belts shown along with the high press PS line where it attaches to PS pump.  This was a very nice discovery: the VR6 pipe is bent just perfect for the TDI PS pump.  

PS pump low press line viewed from L side.  Engine getting very close to completion.

Clutch hydraulic line installation:

 
The big round canister on the L is the brake booster and just to the R of it about midway down you can barely see a grommet that goes through the firewall (see below to orient).  This is the factory hole for the clutch hydraulic line.

Grommet removed and interior insulation visible through firewall.

Close-up of hydraulic line hole (yellowish circle).

Clutch hydraulic line.  This will be snaked through the hole above and sealed up with factory exit grommet where it comes through the firewall.  The end on the R will attach to the clutch master cylinder and the end on the L will attach to the clutch slave cylinder.

Clutch fluid supply line shown next to the factory pinched off barb/nipple on the brake fluid reservoir (fluid is shared between the two systems).  The sealing pinch is only found on automatic models, but VW is kind to us sometimes and this only requires the operation below to use with a manual trans. and hydraulic clutch system.

The end of sealed barb being snipped off and clutch master cylinder supply hose quickly installed.

And just like that the clutch hydraulic system is complete.   Clutch hydraulic line can be seen just below the supply line and just to the R of the brake booster.

'99 Eurovan TDI conversion & manual trans conversion

Our big achievement today was figuring out the L axle situation on this 99 EVC.  The auto trans L axle is 10mm shorter than the manual one for this model, and since there are a sum total of ZERO model year 1999 Eurovan's in this country stock with manual trans. finding that particular yr/model is an excercise in futility and longevity.  Also, after the fitment on Fri of an early EV L side manual axle was deemed unsatisfactory by QC (me), we've been doing some head scratching and some double/triple checking to confirm our findings.  As it turns out the early 93-95 manual trans. EV models DO use the same axle as the later 96-02 models when converted to a manual trans, in this case an EWB 02B.

Don't worry, we have pics:

On L: Manual EV L drive axle 470mm
On R: Auto EV L drive axle 460mm

Rebuilt manual drive axle installed.

Shock re-installed, fasteners torqued to spec.

Undercarriage view with  fuel tank removed.

















Radiator fan resistor pack re-location:

To make room for our FMIC install, we had to re-locate the radiator fan resistors from the center of the front rad core support to the far L.  This worked out very nicely and is about as stock as a custom re-location gets--no wires cut, just lengthened from the bundle and re-covered with split-loom conduit.  

 The dark region on the lwr right is where this resistor pack use to be located.











Replacing shift linkage bushings:

Shift linkage bushings being replaced with new kit.

Linkage ready for re-assembly.













Fuel tank/sender mods cont:

Tank sender/pump retrofit for diesel fuel and TDI eng.  Viton hose shown connecting tank sender top to pump housing (pump removed).

Pump housing shown with pump removed.

Trip report: Salem to Corvallis towing 98 Jetta

Update from last Friday:  Our good friend from the far east found us a donor 98 Jetta for a song up in Salem, so late in the day I made tracks up there to get it with my TDI Eurovan with a tow dolly.  Total mileage on the way there was 35.4 mpg towing the empty dolly.  Some other random data points on the outbound trip:

65 mph
2620 RPM
9.0 psi boost
39.2 MPG
850* F EGT (exhaust gas temp, pre-turbine)
60* F IAT (intake air temp)

My EV did great on the return trip, and for towing I really like the low gearing of the CHP trans (1-4th anyway).  Mileage for the return trip to Corvallis with Jetta in tow was 28.8, with a combined total avg round trip of 32.1 mpg.  Here are some gauge pics of the return trip on I-5 towing the Jetta back to Corvallis:

This pic is climbing the Salem hill just south of Salem on I-5.  Doing this hill in 4th gear to compare EGTs, which are holding right about at 850* F.  Jetta in tow.

And this pic is in 5th gear coming down the other side of the hill.

And one more in 5th at 60mph.

'99 Eurovan TDI conversion & manual trans conversion: day 8

Bit of wheel spinning today trying sort out the L side drive axle issue.  The early T4 L manual trans. axle we got today all but fit, but in the end it doesn't quite meet my satisfaction (appears to be a smidgen short).  After doing lots of research with the help of my Russian colleague ;-), we determined that that P/N should also fit the later EV w/ man. trans. so we ordered another one of the same axles to try fitment again tomrrow.  We're hoping that the axle was mislabeled or in the wrong box, but we realize that might the odds.  In any case we have plan B and C- in place if this new axle doesn't fit the bill.  No pics today--CV joint grease is not conducive to photo taking.

'99 Eurovan TDI conversion & manual trans conversion: day 7

 And on the seventh day they rested.  

Well in Eden on some sultry day, but not in the Grease Works shop when there are wrenches to turn.  We were busy OSU beavers today inching our way closer to completion of this sweet conversion.

Here's the play by play:

 Serp belt installed on eng.  PS pump and belt still awaiting installation.

 Fuel tank mods: In order to modify the fuel filler neck to accept a diesel pump nozzle, and in order to modify the pump/level sender unit to work with the TDI eng we have to pull the tank. 

Tank straps removed, level sender wiring disconnected, fuel lines disconnected, gas sprays in eyes, hair and mouth and so on.

 Tank on floor with filler neck reducer being removed--our patented tankeochtomy procedure.

 Filler plate showing gas filler reducer in center.

 With reducer removed.

 Fuel pump/sender removed.

Being disassembled down to the bones.

Pump/level sender assembly fully disassembled.  Pump will be removed and fuel hoses will be replaced with 100% Viton hoses and fitted to pick-up/return to the bottom of the sender.










Side note:  As requested by our Keeder friend, here we are exploring the solution of a problem many EV owners have: How to fit your full-size spare tire in the stock rack if you have larger-than-stock 16" tires?  Here's how: get the correct parts from VW:

 Spare tire carrier comparison: Stock 99 EVC on the L, 16" on the R.

 These look essentially the same from this angle but the 16" one has a much steeper/deeper 'angle of approach' where the tire sits against on this side.

 16" spacer and sleeve on L, stock hardware on R.

 16" bolt on L, stock bolt on R.

 16" tire installed on carrier.







Plenty of room to snug down the tire.

Shown for comparison of angle on R side.  Deeper bend fits the bigger tire.

'99 Eurovan TDI conversion & manual trans conversion: day 6

Time for the nitty gritty details of conversion work:

 VR6 120A alternator and AC compressor fit the TDI bracket perfectly and in fact share the same P/Ns.  Due to its larger diameter and offset position, the VR6 alt pulley was removed and replaced with an AHU pulley.

 Happy family of engine pulleys.

 AC compressor lines going to comp.

 Another view of AC comp lines.

One by one we go through and plug in connectors and wires, tidy up this and figure out that.  Rebuilt Bosch 5-spd starter shining like a black gem.  Trans mount upper right corner.

R side engine mount and bracket.  Look at all that room TDI dreamers!  You can actually work on this engine!!