Shop cleaning: Misc parts for sale

When I first started rebuilding VW engines and built my first diesel (VW 1.5l NA!) in a cabin in Wren, Oregon by the wood stove one snowy winter,  TDIs where not even a reality in my orbit.  At that time the internet was barely off the ground, dial up and AOL were king and all tech info came from the Bentley or the Poor Richard's classic tome, "How to keep your Rabbit Alive".  VWdieselparts.com was the mecca, Jack the kind and saintly sage, and the 1.6TD engine was the holy grail and the fastest way to achieve VW diesel Nirvana.  Imagine that?  My how things have changed.  While still a respectable lil power plant and a great diesel engine to work/learn on my shop and diesel inclination/fascination has moved us towards the next generation of VW diesels, the TDI.  This leaves me with lots of good tools/parts that after shedding my fair share of blood sweat and tears with I'm now ready to part with.

As I clean the shop this spring at each corner I am discovering gems from that era that would no doubt still sate the appetite of many--from the shade-tree DIYers to the up and coming dubbers cutting their teeth on the A1/A2 VW diesel platform.  So here you go, a few little hard-earned things that I'm finally ready to part with, with more to come shortly:

 Build your own 1.6TD Injection pump!  A great beginner project for the well initiated.  These are the guts from a 1.6TD IP (non-JX model) cleaned up and ready to turn your NA IP into a true TD IP.  Includes everything pictured but no guarantees it's complete!  Been sitting around too many years for me to be sure.  The boost pin appears to be from the 1.9TD IP which is considered inferior to the 1.6TD pin BTW (top R in pic).  $90 including S/H to the lower 48 states.  If you want a Bosch seal kit to for this IP include an extra $20.  Combined with IP below and a seal kit for $150 shipped lower 48.

 We used this IP for display at fairs and expos during our grassroots biodiesel days.  Most of the IP guts are still intact, with the top cover, cold start cover/arm, throttle arm and distributor head removed for viewing.  Again, "probably" complete, but not guaranteed.  Too long opened to know for sure.  $50 including S/H to the lower 48 states.  If you want a Bosch seal kit to for this IP include an extra $20. 

When is the last time you checked and adjusted the breaking pressure of your injectors??  You want to run 155 bar, then shim the injector till it gets there.  Bosch injector shim assorted box.  These are Bosch factory shims for all 1.5, 1.6 and 1.6TD injector nozzles.  These little suckers are precision milled shims not production run washers and they were spendy and hard to source back in the day.  Multiples of most sizes.  $75 shipped lower 48.
 If you're interested in a factory Bosch injector tester (AKA pop tester) let me know (justin@greaseworks.com), I might be willing to sell mine to some intrepid soul.

Eurovan automatic transmission cooler upgrade.  This is everything you need to give your inherently hot running EV auto trans the cooling it needs.  New ports screw into trans and eliminate the engine coolant that "cooled" it from the factory and gets you front mount cooling via this radiator.  Slick and efficient, a no brainer for anyone running an automatic EV.

 Vanagon 86-91 AC switch assembly.

Top view.  Includes pigtails.

 Rear view.

Spring snow and escape to Monterey

It's been wet, really wet here.  Sometimes it gets very old especially when the second day of "spring" at the valley floor looks like this:

But this is a fluke, a freak month of near record precip that must be a rude joke by good ole mother nature (even with those eons-old chewed up teats she can still lay a good one on us!).  So we regain a small semblance of comfort and head south to sunnier environs: Monterey, CA.

Fill up at biodiesel station in Pheonix, OR.

Our 93 TDI EV loaded down with the family, provisions and 4 bikes.

B99 for $4.24/gal.  Cheaper by a quarter than all the freeway diesel pumps from Monterey to Corvallis.














On long road trips like this, especially when we drive all night red-eye style (6pm-6am time slot for ease of kiddos), and everyone is asleep I dream of big performance mods, stacked compounded turbos and 50+psi boost.  Will it ever happen? That I don't know, but it always starts with a dream so I guess I'm part of the way there :-).  For now my humble little TDI EV w/stage III build/tune 20psi max is just a dandy and a great way to pass the miles on the open road.  And at 30+mpg it's tough to beat in terms of functionality.

Splendid Garden Eels

Other than the sunshine, another great reason to go to Monterey!

Easily overlooked and likely to be missed by even a sneeze is the Splendid Garden Eel exhibit at the Monterey Bay Aquarium.  I could spend a whole day in somnolence just staring at these little guys....

84 Vanagon Westfalia 4-spd 1.9L WBX Westy

Up for sale is a great entry level 84 Volkswagen Westy from Cali with a stock 1.9l engine and a 4-spd manual trans with 240k miles.  Cosmetically not perfect but a good starter for someone who wants a budget Westy willing to give it cosmetic attention here and there.  Starts right up and zips around nicely. Ready for the long haul?  Maybe.  I'd personally take it cross-country tomorrow but it would be best to get to know it around town for a few weeks first.  

This is a factory full Westy with poptop, stove, fridge, sink and cabinetry, upper and lower beds, etc. Manual windows and door locks, factory AC (currently inop), stereo present but not working. Dash heater and rear heater work great. Comes with some extra parts (starter, etc)

I recently put in about $2k in service work including: new front heater core & blower motor, tune up (plugs, wires etc), rear brake shoes, front brake caliper, ignition switch, hatch struts, etc. Also new pop-top seals and new 3-window poptop canvas by previous owner. I got this rig last fall as part of some VW horse trading, but now I've run out of time/money on restoring it and I just need to let it go for a bargain. This van has been re-painted over the stock sandstone (orange) color and in places you can see this. Needs a little attention here and there but is a good starting point for someone's summer road adventures. No pending mechanical issues that I am aware of.

Cash talks and reasonable offers considered. Lowballers need not inquire and tire kickers please don't waste my time. Clear title in hand and currently has OR temp tags good for the next 3-wks. Located in Corvallis, OR.

VIN: WV2ZB0250EH133426 


Asking $4500.  Email me if you are interested.







Thanks,
Justin

The Good:

From 20' it's a looker!

 The indifferent:

Der nicht so gut:

Dent aft sliding door.  Original sandstone paint visible at jack point.

Dent at rear R corner.

Minor imperfections fore L door

Slight bubble rust at windshield

Seem imperfections R front corner.

Paint chips R front corner

Original paint peeking through front.

Dent R front corner

Imperfections L rear 1/4.

Slight seem corrosion L rear 1/4

Bubbled paint/seem corrosion L mid panel

Wavy bumper rear.

Dent front L.

TDI injection pump distributor head O-ring Viton

These are now available separately from the full Bosch kit we sell here.  This O-ring fits all Bosch VE injection pumps from 1977-2003.   The distributor head is the part of the pump that the injection lines attach to, and where it mates to the IP is a common place for leaks due to a failed/flattened/frustrated O-ring.  This is something that with great patience and a modicum of skill can be replaced in situ without removing the IP from the vehicle.

It's worth noting that as of 2011 all of our TDI conversions now include a rebuilt TDI inj pump with new Viton seals.

Available here: https://www.greaseworks.com/store/product_info.php?cPath=27_40&products_id=693

TDI/VW Bosch VE distributor head injection pump Viton O-rings:

New diesel Vanagon carrier bars, 2wd and Syncro

This is the first new production run of these in over two decades!  These are an exact duplicate of the NLA diesel Vanagon 2wd and Syncro carrier bars made here in the US by an independent engineering firm in Oregon (TSI engineering).  Quality is top notch both inside and out and finished with black powder coating.
Now available at the Grease Works online store:
2wd Diesel Vanagon carrier bars
Syncro Diesel Vanagon carrier bars

All the Vanagon diesel NLA gods bring and more:

New 2wd diesel carrier bars

New 2wd diesel carrier bars

New 2wd diesel carrier bars

 To my eye there is something subtly sensuous and inviting to the curves of the carrier bars in this pic....  

Not quite strict anthropomorphism, but what do you call it when you attribute human characteristics to inanimate objects, namely car parts?

New 2wd diesel carrier bars

Old stock OE 2wd carrier bars L, new 2wd diesel carrier bars R

New 2wd diesel carrier bars L, old stock OE 2wd carrier bars R

Mount bracket inside detail.

Mount bracket outside detail.

Syncro diesel carrier bars

2wd diesel carrier bars L, Syncro diesel carrier bars R

Syncro diesel carrier bars L, 2wd diesel carrier bars R.

Syncro diesel carrier bars (two in middle), and a stray 2wd bar far R

85 Vanagon TDI stage III conversion

Yes yes, I know another engine build and another conversion getting underway.  This one should be straight forward enough to get it out the door within a few weeks.  1985 Vanagon Westy w/1.9 WBX and 4-spd trans getting a stage III TDI 1Z engine build along with a rebuilt/re-geared 4-spd trans with LSD, oiling plates, and 1.08 3rd and .70 4th.

Old 1.9l WBX engine/trans:

1.9l TDI 1Z Engine build:

 1Z block on stand crank laid, main bearing clearances checked and new bolts torqued to 48 ft/lbs + 90*.

 0.50mm over ASV pistons queued up for installation onto rods.

 Rods at the ready.

 With copious assembly lube pistons mated to rods.

 Pistons installed in eng and rod radial clearances checked.  Rods 2 and 3 in spec.

 Rods 1 and 4 in spec.

 Pistons installed and height projection being measured.

 ARP head studs installed and alignment studs on the diagonal corners to keep the head gasket perfectly aligned.

 Oh the beauty of new pistons in a rebuilt engine...

 Rebuilt cylinder head poised for sealing surface de-greasing.

 Cleaned up and ready for mating to short block.

Head mated, centering studs removed and head studs torqued to spec. Long block complete.

 Intermediate shaft pulley torqued and marked.  Torque spec on these is 33ft/lbs but through life's cruel lessons we have learned that's not enough and always torque them to 44ft/lbs AND use red loctite.  You do not want this bolt backing out on you!

A new elegant solution for the turbo oil supply line: Instead of the stock OE rigid steel pipe KermaTDI came up with this simple and sweet flexible stainless high press hose with the correct fittings on each end for the AHU/1Z with oil feed coming off the oil filter flange and not the cyl head (early 1Z).

The stock oil supply pipe is notorious for developing cracks resulting in deal breaking end of trip results with high pressure oil leaking EVERYWHERE.  The veritable Achilles heal of the AHU/1Z engine.

 Progression of an EGT probe install by the Freehand Machinist Artisan:

1) Ideal probe site is identified and then checked with turbo installed on eng to verify clearances.
Test incisions made to assess suitability

 2) Site is machined to provide a flat surface without side interference for 1/8" NPT probe install.

 3) Bit by bit the two planes are taken down with constant inspection inside to ensure suitable material thickness.

 4) Continued material removal until

 it's just

 right.

5) Mirror image cut with plenty of material for tapping and just enough room on the side.

 Clutched up! This is our STD heavy duty hybrid G60/WBX clutch set up we use now on our Vanagon TDI conversions: Lightened G60 flywheel (228mm), WBX disc (228mm), G60 pressure plate.  This set up can hold over 320ft/lbs torque and we've yet to find their slipping point even on our biggest builds (stage VI).  And on top of all that with this flywheel you can still remove the oil pan without removing the trans which isn't possible with the stock AHU/1Z flywheel.












Another view of our hybrid clutch set up as well as the new flexible SS turbo oil supply line.

 Rebuilt WBX tranny from GTA with 1.08 3rd gear, 0.70 4th, limited slip diff (LSD), SA oiling plates, reinforced case, etc.  Premium built 2wd trans.

 D side view of trans.

Build tag from tranny shop.














Intercooler time:

 View from below, turbo and L carrier bar.

 Intercooler system plumbing.

Electrical junction box--where the magic happens.

Installed TDI engine with coolant system complete, fuel system complete, power steering system complete, intercooler system complete, air intake system complete and wiring nearly complete.

Cluster mods

 Customized Vanagon cluster modified with check eng and glow plug light, tach to read TDI tach output signal, and two digital Auber gauges (L about headlight switch), to read EGT and boost or oil temp etc.  Slick, sleeper and stock.

 

***All pics and conversion work done by TDIpowered.