Volks, I took my `82 Westy Diesel ("Tortuga") in last night for what I hope will be the transformation of it's and my lifetime. The new 1.9TD is supposed to arrive today for the swap ( I hope). Thanks to all who contributed on the list, especially, John at VW Bus, for the handy gearing program he sent.
As it stands, without putting in a new (or used) 5 speed, I have a choice of redoing my existing 4 speed with a 5.50 ring and pinion for a top end of about 69mph @ 4000rpm or a 4.57 r&p for 82mph @ 4000rpm. I wish there was something about in the middle but I've been assured that there isn't for my tranny. The list of trannies that Helmut sent shows one with a 4.86, which would be ideal. Anyone know of a source for that R&P gear?
At any rate, the old (but still good. Anyone need)1.6L is coming out today. The die is cast and I'm holding my breath.
Bob Bellanca
Well, My new 1.9L TD finally arrived on Wed. I've been ohing and ahing ever since. This is quite a spiffy motor, looks like it will just be a drop in. Modifying the engine mounts does not seem necessary, as is the case when using a 1.6L TD from a Jetta or Rabbit. The turbo is much smaller, so it appears there'll be plenty of clearance. The unit came with a factory exhaust pipe which will have to be cut and redirected but no problem, just having the flange was more than I'd hoped for...
Things to resolve:
I'm having my old DZ tranny rebuilt with 4.57 ring and pinion and original gearing. That should be as sufficient as any, short of a five speed. It should be back about Wed or so. Lots to do.
Bob Bellanca
Well, it's official... I now have a running, snorting, seething 1.9L TD in the Westy that works. After returning the tranny back to the rebuilder ( I. T. S., El Cajon, Ca.) and having the Lock-Rite locking differential removed. then reinstalling it, I got to drive it for the first time just a few minutes ago...The results blew me away. I now have a rocket ship. I wasn't able to open it up all the way due to traffic but cruising at 75mph, I still had peddle left, going uphill... I'm going to have to put larger tires on it. For those of you who don't drive a diesel Westy, anything over 60 mph is cause for celebration. That van has never seen 70 much less 75. One thing I'm going to do is put tires with stiffer sidewalls on. Not having attained those lofty speeds before, the XZX's that are on there seemed fine. With the new top end, I'm going to have to rethink the tire setup. Anyone know offhand what the largest tires fit a stock setup without rubbing or bottoming out? I'm sure it's in the archives somewhere but right now I'm a little to excited to look.
Bob Bellanca
Bob Bellanca
What the mods have done to the van: I am no longer relagated to the right hand lane. At 3100 rpm I am doing 65 mph, at about 3600 rpm about 75 mph. I no longer have to anticipate every single time I pass another vehicle.(Especially on two lane roads).
What I've learned: This is a very straigh forward engine swap. A good mechanic can probably do it in about 8 hrs, if he has all the parts needed. The most difficult part is comming up with a suitable air filtration system. What I've come up with is a hybred, scavenged from bits and pieces of other vehicles. It may not be the most ideal intake but for the right now, it's fine.
Would I do it again: YOU BET! However, the next time it won't take so long...
Bob Bellanca
For those who like Diesels, Just returned from the maiden voyage (of over 100 miles) with the 1.9L TD. Went up to No. Cal to visit my kids and this is what I've found...
With the 4.57 R& P, going over the Grapevine (north), the slowest speed attained; 52mph in fourth (only the first few miles straight up, then 70mph).On the way south, the same ( going straight up to 4000 ft) 52mph.
On the way north I tried 65mph the whole way; mileage 23.5. South, 70mph, 21.5mpg. This is a touch less than the 26-27mpg I used to get with the old 1.6L but, what the heck, I never had to think about passing or changing lanes...
At the steepest part of the "Grapevine". the oil temp got to 250 deg F, otherwise, it stayed at a comfortable 210 deg...Interesting, the oil temp stayed well below that at 60 mph (about 190 deg). Also, the boost at 4000ft with full throtle was almost 14lbs, as opposed to 11-12lbs on the flat (at full throtle). I guess the alttitude compensator works.
The nominal flat out high end is 78 mph ( at 4000 rpm), this can be achieved at any time I choose, as opposed to 60mph down hill with a tail wind...An altogether different experience...
Who knows, I may start driving it up here in the States...
Bob Bellanca