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Old 29th July 2013, 19:07   #31
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Default Re: My TD to TDI VW Van (1990 model)

Heart warming to see the love you have for VW Van. Once classic piece this is. Great job till now
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Old 30th July 2013, 10:34   #32
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Default Re: My TD to TDI VW Van (1990 model)

Great work. Just the thought of fixing a front wheel drive engine on to a rear wheel drive vehicle would put off most people from the job. can you put a word on the donor octavia/laura? was it a totalled car or you got a used one just for this this job? real chop shop stuff!
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Old 30th July 2013, 10:36   #33
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Default Re: My TD to TDI VW Van (1990 model)

Great stuff man. The odometer exchange and the monitor is super cool. By the way, are you planning to add some more modernity to the van?
Because I personally felt from the pics that the steering wheel and that gear rod including some tiny bits and pieces are taking away that modern feel from the dash.
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Old 30th July 2013, 12:49   #34
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Default Re: My TD to TDI VW Van (1990 model)

You ought to rename the workshop where your van is being reborn to 'Deccan Valley Customs'. Top work there mate. A full on customisation which a modern engine swap is the stuff of dreams for most of us. Any particular reason why chose the Skoda Laura engine over, say a Jetta PD TDi engine? I'm sure you have done enough research on it, but would love to know.

I was working for a VW dealership for a few years so I do know that VW does a lot of parts sharing amongst VW, Audi and Skoda. I have seen a few modernised VWs in Europe running state of the art TDi and TSi engines. Of course, they have enough resources over there, but much respect for doing something like this in India.

Do keep on updating. The van's transformation is quite interesting.
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Old 30th July 2013, 16:00   #35
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Quote:
Originally Posted by crdi View Post
. Just the thought of fixing a front wheel drive engine on to a rear wheel drive vehicle would put off most people from the job. can you put a word on the donor octavia/laura? a !
It's gear box used holds the key not the engine.Van gear box & Laura engine mated bolt on, no modification. I used a totaled car engine. located in Chennai.

Quote:
Originally Posted by madhav14 View Post
Because I personally felt from the pics that the steering wheel and that gear rod including some tiny bits and pieces are taking away that modern feel from the dash.
There is lot more to go. Regarding steering wheel I am going for electrical PS & yes, it's speed sensitive I have located it. It's bolt on. Then will be going for small dia wheel I will up date.

Last edited by Eddy : 18th August 2013 at 23:18. Reason: Merged
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Old 30th July 2013, 16:38   #36
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Default Re: My TD to TDI VW Van (1990 model)

Quote:
Originally Posted by narendra.vw View Post
There is lot more to go. Regarding steering wheel I am going for electrical PS & yes, it's speed sensitive I have located it. It's bolt on. Then will be going for small dia wheel I will up date.
Wow, that's super cool man. Looks like you are competing with DC guys.

Waiting for the updates.
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Old 30th July 2013, 17:01   #37
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Default Re: My TD to TDI VW Van (1990 model)

Quote:
Originally Posted by coloneljasi View Post
Any particular reason why chose the Skoda Laura engine over, say a Jetta PD TDi engine? I'm sure you have done enough research on it, but would love to know.

.
PD TDI engines are very hard to find in India.The only advantage in PD is lesser noise. same engine block. They don't carry single Distributor pump like TDI, they have pump for each cylinder inside the valve door operated by a cam. very interesting.
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Old 30th July 2013, 18:01   #38
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Quote:
Originally Posted by narendra.vw View Post
PD TDI engines are very hard to find in India.The only advantage in PD is lesser noise. same engine block. They don't carry single Distributor pump like TDI, they have pump for each cylinder inside the valve door operated by a cam. very interesting.
That is true. How did you sort out the complex wiring and the OBD connector? The VAS tester will detect your van to be the donor Laura, as you have swapped over its identity. It all seems like a herculean task to me. Especially since this is all being shoehorned into a generations old van. On the flip side, I can imagine that the van, post heart transplant, will be a hoot to drive.
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Old 30th July 2013, 20:31   #39
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Default Re: My TD to TDI VW Van (1990 model)

This Thread felt like a fish out of water. Well it was wrong . I bought this thread for the general knowledge. I know, not every one can do it.

One more note. Any modification done until now had only one shot to do . No spares so no second chance.


Extension of wiring . You will find some of German innovative way of thinking.


Unique Speedo design.. Cable starts from front wheel dust cap ends with speedometer, nothing in between.
My TD to TDI VW Van (1990 model)-dustcap.jpg
My TD to TDI VW Van (1990 model)-speedo-2.jpg

Speed sensor of TDI getting ready to mate with TD cable.
My TD to TDI VW Van (1990 model)-speedo-1.jpg
My TD to TDI VW Van (1990 model)-speedo3.jpg

speed interface used to recalibrate and send right signal to the cluster.. USA make.
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Location of interface & speed sensor.
My TD to TDI VW Van (1990 model)-closer-look-ecu.jpg

TDI fuel float sensor chip fused into TD float. quite brainy yes? Sad thing was I had to discard whole TDI float assembly . Used only 10% of it. I hate to cut the fuel tank.
My TD to TDI VW Van (1990 model)-fused-float.jpg
My TD to TDI VW Van (1990 model)-float.jpg

Acc pedal. I didnít like the angle of the TDI pedal so I used my TD into it. Now my ankle is happy.
Yes now my van is fly by wire.
My TD to TDI VW Van (1990 model)-acc-cable-1.jpg
My TD to TDI VW Van (1990 model)-acc-cable-2.jpg
My TD to TDI VW Van (1990 model)-acc-cable-3.jpg

Tail lamp wiring.
My TD to TDI VW Van (1990 model)-tail-lamp-wiring.jpg
Tail lamp when itís lit.
My TD to TDI VW Van (1990 model)-tail-light-working.jpg

sun visor . 1990 they think of this & still works. Happiest person, my wife for this.
My TD to TDI VW Van (1990 model)-sun-viser.jpg
My TD to TDI VW Van (1990 model)-sun-viser-.jpg
My TD to TDI VW Van (1990 model)-viser-.jpg

Centre row lighting.
My TD to TDI VW Van (1990 model)-roof-light-.jpg

Photo taken without flash.
My TD to TDI VW Van (1990 model)-non-flash-light.jpg

Front blower knob (Hot air only) extreme right.. Rest is for AC control.
My TD to TDI VW Van (1990 model)-ac-nob.jpg


Using two alternators one for the van battery other for charging acc battery . Acc battery will be used for ? Later.
My TD to TDI VW Van (1990 model)-double-alternator.jpg

This is interesting . Since back row passengers find it difficult to reach the lever I came up with this idea. Any one who has sliding door can think of this. There are three solenoid switches meant for centre locking. One I have used for locking Two I have used for catcher opening.
My TD to TDI VW Van (1990 model)-auto-lock.jpg
My TD to TDI VW Van (1990 model)-lever.jpg

Contact points.
My TD to TDI VW Van (1990 model)-cimg1169.jpg


Left is for my bosch horn ( been with me for over 20 yrs.) right is for sliding door catcher opening.
Bottom centre, unique. Itís a simple pull & push jeep H/L switch, but it working, little different.
Focus please, first pull, extra light on, second pull extra light off but it is connected to high beam of the H/L. When high beam is switched on all four lights comes on. Go to Low beam the extra light goes off. Pushed all the way back ,will switch off extra light.
My TD to TDI VW Van (1990 model)-extra-horn.-light-catcher-switch1.jpg


Back passenger hand rest with door catcher switch.
My TD to TDI VW Van (1990 model)-switch-back-seat.jpg


Just for the knowledge. vacuum layout
My TD to TDI VW Van (1990 model)-see-vac-route.jpg

Next time I will back with air supply .
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Old 31st July 2013, 21:09   #40
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Default Re: My TD to TDI VW Van (1990 model)

Air intake route details.

Air mass sensor
My TD to TDI VW Van (1990 model)-side.jpg
air filter to turbo hose
My TD to TDI VW Van (1990 model)-airfilter-toturbo.jpg
starting of air filter
My TD to TDI VW Van (1990 model)-air-filter.jpg
ends at turbo
My TD to TDI VW Van (1990 model)-turbo.jpg
firmly clamped
My TD to TDI VW Van (1990 model)-hose-firmly-clamped.jpg

inter cooler to be fitted.
My TD to TDI VW Van (1990 model)-cut-ic.jpg
Inter cooler
My TD to TDI VW Van (1990 model)-intercooler.jpg
inlet hose
My TD to TDI VW Van (1990 model)-turbo-intercooler.jpg
Route of air intake
My TD to TDI VW Van (1990 model)-hose-pipe-route.jpg
turbo to inter cooler
Click image for larger version

Name:	Hose pipe route.JPG
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turbo out
My TD to TDI VW Van (1990 model)-turbo-out.jpg
To inter cooler
My TD to TDI VW Van (1990 model)-intercooler.jpg
Inter cooler to inlet
My TD to TDI VW Van (1990 model)-intercooler-inlet.jpg
complete
My TD to TDI VW Van (1990 model)-plumbing-complete.jpg

Exhaust
My TD to TDI VW Van (1990 model)-silencer.jpg
My TD to TDI VW Van (1990 model)-finished-silencer.jpg
fitted to the engine
My TD to TDI VW Van (1990 model)-route.jpg
My TD to TDI VW Van (1990 model)-silencer-mount.jpg

Just for knowledge I love to fabricate such a body jack
My TD to TDI VW Van (1990 model)-body-jack.jpg
Attached Thumbnails
My TD to TDI VW Van (1990 model)-air-inlet-route.jpg  

My TD to TDI VW Van (1990 model)-air-vent.jpg  


Last edited by narendra.vw : 31st July 2013 at 21:14.
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Old 2nd August 2013, 21:13   #41
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Default Re: My TD to TDI VW Van (1990 model)

flooring finished
My TD to TDI VW Van (1990 model)-floor-polished.jpg
roof ac fixed
My TD to TDI VW Van (1990 model)-ac-duct-roof-fix.jpg
middle seats
My TD to TDI VW Van (1990 model)-back-middle-seats.jpg
back row seats
My TD to TDI VW Van (1990 model)-back-seat1.jpg
space utility
My TD to TDI VW Van (1990 model)-drawer-seats.jpg
jail bar protection for back glass
My TD to TDI VW Van (1990 model)-more-door-jail-bar.jpg
bedding for gear box
My TD to TDI VW Van (1990 model)-more-power-flex.jpg

ac working. just for knowledge
Name:  airconditionrepair.jpg
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Size:  171.8 KB

Thanks for all of you who had shown keen interest, viewed & Replied this thread.
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Old 5th August 2013, 11:54   #42
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Default Re: My TD to TDI VW Van (1990 model)

Thats a lot of dedication and detail there. Kudos to your patience in rebuilding the old VW van. Just two words though not enough....Simply amazing.
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Old 7th August 2013, 14:23   #43
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Default Re: My TD to TDI VW Van (1990 model)

Great job on the van, its coming along really well. I really like what you've done with the interior. However you really should consider getting a great set of wheels and tyres. Just like shoes make the man, wheels make the car!!
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Old 11th August 2013, 16:36   #44
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Default Re: My TD to TDI VW Van (1990 model)

Quote:
Originally Posted by spawnofsatan View Post
Great job on the van, its coming along really well. I really like what you've done with the interior. However you really should consider getting a great set of wheels and tyres. Just like shoes make the man, wheels make the car!!
Thanks. Regarding wheels I had hard time in finding my requirement disc, finally I found a set of 4. Make OZ, Italian made. DIsc info: 15" 6J 5 hole 112 pcd. Tyre yet to deside

Last edited by narendra.vw : 11th August 2013 at 16:38.
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Old 11th August 2013, 17:39   #45
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Default Re: My TD to TDI VW Van (1990 model)

Thanks, for bumping this thread. In my last posting I skipped lot of details., reason I felt like talking to my self. I need your feed back to go forward. I expected lot of curiosity from TDI owners (Skoda, polo, Audi ) Any comments accepted with same sprit.

BACK TO WORK
Regarding work, lot of it yet to be finished. Tyres , wind shield, new gear box bedding, front part flooring, proper roofing. New Air filter.

Tyre:- To tame the torque I have to up grade my 14Ē disc to 15Ē. At 120 kmph engine screams at 3200 rpm I want to bring it down bellow 3000rpm. As of know van matches Innova in speed or pickup if not more.

Wind shield:- van had a broken one from day one when I bought. Luckily I could find one in Bangalore .It has dark green ting at the top good in summer days.

Flooring & roofing:- Now a days itís hard to find good dedicated liners who do other than routine work. Seat work plenty .

Gearbox bedding :- Up grading . Virus starts from gearbox to steering box & spreads to suspension depending on my bank balance.

New air filter:- My air mass sensor is not accepting present air filter.

TYRE DISC:-- 6J 15Ē 5hole 112 pcd
TYRE:-- 205/ 15Ē/ 70 A/T.

I will be back with photos & details.
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