I'm converting my bay from 1.9D to 1.9TDI. To get there I have to rip everything out and start again. So the current setup is going to be for sale.
The details:
1.9D engine from a mid '90s Vento. The car was maintained by my dad for a customer for most of its life so had a known history and maintenance record. When I got it, I treated it to a timing belt & tensioner, new water pump, thermostat and a few new gaskets.
the gearbox is a "6-rib" box from a late 2.0 bay. It's got the highest final drive of any 4-speed bay transmission so was the best one available for the diesel conversion.
the adapter kit is from KEP in the states. It's an aluminium adapter ring and custom steel flywheel and it comes with a new pilot bearing for the end of the crank to support the input shaft of the gearbox. The Vento never needed this so it has to be fitted for the conversion. I fitted a new clutch shortly before I did the conversion so I kept it with the engine.
the starter motor is a standard item from a B4 TDI passat and it fitted with an adapter plate I made myself. It's a 2kW starter motor, it's massively powerful and perfect for the diesel compression.
the support subframe I made myself being very careful to isolate as much vibration as possible, the engine is mounted to the subframe using the stock Vento mounts and then the subframe is mounted to the van using the stock mounting points with another set of rubber bushes, further isolating the engine from the van.
the exhaust is a stock type25 diesel silencer with a custom welded downpipe including a flexi section. It's rubber mounted to the subframe to isolate it from the body.
I was going to keep the radiator and ducting under the van as it'll work equally as well with my TDI. However, if the right offer is made, it can go too. It's a stock type25 diesel radiator, mounted to the chassis rails with a carefully designed sheet metal ducting surrounding it, drawing clean air from in front while keeping road dirt out and venting the warm air out the back. It's got a new slim-line fan mounted inside the duct too.
Aside from the starter motor adapter, everything is built up from factory parts that are available off the shelf. Should anything need to be replaced, it's readily available. The whole conversion can be fitted to a late bay WITHOUT CUTTING THE VAN IN ANY WAY. I.e. it's totally reversible if originality is your thing. The only modification is a few holes have to be drilled in the chassis rails to fit the ducting and rad. The original wring of the van isn't tampered with either, the diesel engine needs only a few wires to run.
I've had the conversion in my van for two years now and 9300 miles. It hasn't missed a beat! Not once. It'll be due an oil & filter service in 700 miles time but I'll do it before the sale. It's no secret that I'm a fuel economy nerd and I've been keeping a fueling record here:
http://www.fuelly.com/car/volkswagen/kombi/1974/trevorbrady/218403
you can see how many miles I've done, how often I've filled it, where, notes on what kind of driving it got etc. The average MPG has been averaging at 35.5MPG with an all-time best of 41.3MPG. Those figures easily doubled what I was getting with the old 1.8 type4 petrol engine. Plus the diesel is cheaper! This is in my late Westfalia, I'd expect better figures from a lighter microbus or a more aerodynamic tin-top bay.
This is a straight bolt-up conversion for a late bay, the chassis rails are different as far as I know in an early bay so it'll need some extra work to get it to fit. My van is at stock height and I've never once caught the radiator duct (the lowest point) on anything. If your van is lowered, you may run into difficulties.
Full build-thread here:
http://www.eircooled.com/deforum/showthread.php?9297-Diesel-engine-conversion-in-my-bus
price: €2000 for everything including the radiator, ducting, low-friction throttle cable etc. If you want to go with a front-mount radiator then I'll keep my setup and we can negotiate a discount.
If you're very quick you can take my van for a test drive before I remove the conversion. You'll have to fit it to your van yourself or get one of the aircooled specialists to fit it for you. It's very straightforward, all the hard work is done for you...
The details:
1.9D engine from a mid '90s Vento. The car was maintained by my dad for a customer for most of its life so had a known history and maintenance record. When I got it, I treated it to a timing belt & tensioner, new water pump, thermostat and a few new gaskets.
the gearbox is a "6-rib" box from a late 2.0 bay. It's got the highest final drive of any 4-speed bay transmission so was the best one available for the diesel conversion.
the adapter kit is from KEP in the states. It's an aluminium adapter ring and custom steel flywheel and it comes with a new pilot bearing for the end of the crank to support the input shaft of the gearbox. The Vento never needed this so it has to be fitted for the conversion. I fitted a new clutch shortly before I did the conversion so I kept it with the engine.
the starter motor is a standard item from a B4 TDI passat and it fitted with an adapter plate I made myself. It's a 2kW starter motor, it's massively powerful and perfect for the diesel compression.
the support subframe I made myself being very careful to isolate as much vibration as possible, the engine is mounted to the subframe using the stock Vento mounts and then the subframe is mounted to the van using the stock mounting points with another set of rubber bushes, further isolating the engine from the van.
the exhaust is a stock type25 diesel silencer with a custom welded downpipe including a flexi section. It's rubber mounted to the subframe to isolate it from the body.
I was going to keep the radiator and ducting under the van as it'll work equally as well with my TDI. However, if the right offer is made, it can go too. It's a stock type25 diesel radiator, mounted to the chassis rails with a carefully designed sheet metal ducting surrounding it, drawing clean air from in front while keeping road dirt out and venting the warm air out the back. It's got a new slim-line fan mounted inside the duct too.
Aside from the starter motor adapter, everything is built up from factory parts that are available off the shelf. Should anything need to be replaced, it's readily available. The whole conversion can be fitted to a late bay WITHOUT CUTTING THE VAN IN ANY WAY. I.e. it's totally reversible if originality is your thing. The only modification is a few holes have to be drilled in the chassis rails to fit the ducting and rad. The original wring of the van isn't tampered with either, the diesel engine needs only a few wires to run.
I've had the conversion in my van for two years now and 9300 miles. It hasn't missed a beat! Not once. It'll be due an oil & filter service in 700 miles time but I'll do it before the sale. It's no secret that I'm a fuel economy nerd and I've been keeping a fueling record here:
http://www.fuelly.com/car/volkswagen/kombi/1974/trevorbrady/218403
you can see how many miles I've done, how often I've filled it, where, notes on what kind of driving it got etc. The average MPG has been averaging at 35.5MPG with an all-time best of 41.3MPG. Those figures easily doubled what I was getting with the old 1.8 type4 petrol engine. Plus the diesel is cheaper! This is in my late Westfalia, I'd expect better figures from a lighter microbus or a more aerodynamic tin-top bay.
This is a straight bolt-up conversion for a late bay, the chassis rails are different as far as I know in an early bay so it'll need some extra work to get it to fit. My van is at stock height and I've never once caught the radiator duct (the lowest point) on anything. If your van is lowered, you may run into difficulties.
Full build-thread here:
http://www.eircooled.com/deforum/showthread.php?9297-Diesel-engine-conversion-in-my-bus
price: €2000 for everything including the radiator, ducting, low-friction throttle cable etc. If you want to go with a front-mount radiator then I'll keep my setup and we can negotiate a discount.
If you're very quick you can take my van for a test drive before I remove the conversion. You'll have to fit it to your van yourself or get one of the aircooled specialists to fit it for you. It's very straightforward, all the hard work is done for you...
