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Old 12th August 2013, 19:54   #46
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Default Re: My TD to TDI VW Van (1990 model)

Adding few more work done to the van.

Cable to unlock middle rear seat.

My TD to TDI VW Van (1990 model)-cable-lift-middle-seat.jpg

Seat unlocked.(locking part:--Gypsy bonnet lock.)

My TD to TDI VW Van (1990 model)-dr-back-seat-tilt.jpg

Access to ECU & main fuse

My TD to TDI VW Van (1990 model)-dr-back-ecu.jpg

Gear lever Pivot point changed. Stroke length is reduced by 25%.

My TD to TDI VW Van (1990 model)-spacer-shifter.jpg

My TD to TDI VW Van (1990 model)-sp-assimble.jpg

My TD to TDI VW Van (1990 model)-sp-finished.jpg

German innovative thinking. Air circulation from front blower to to roof.(Hot or room temp.)

Air comes through duct made in door pillar.

My TD to TDI VW Van (1990 model)-hot-air-1.jpg

Air comes through door duct, yes door.

My TD to TDI VW Van (1990 model)-hut-air-2.jpg

From door it enter center pillar go to inside roof & spreads around
Attached Thumbnails
My TD to TDI VW Van (1990 model)-hot-air-3.jpg  

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Old 13th August 2013, 13:57   #47
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Default Re: My TD to TDI VW Van (1990 model)

Quote:
Originally Posted by narendra.vw View Post
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
Narendra - That sounds great, any pics of the wheels? I see you want to get 205/70/15. have your considered upsizing the tyres? Additional rubber will definitely make the van look better. Glued to this thread !!

Devansh
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Old 13th August 2013, 17:05   #48
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Default Re: My TD to TDI VW Van (1990 model)

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Any pics of the wheels? I see you want to get 205/70/15. have your considered upsizing the tyres?

Devansh
Thanks for your concern, Please hold on a little bit, I will post disc photo once I get the tyres . It will be better to have photo of both. Regarding up sizing I am trying to make the van family friendly.(Getting in & out for aged person)
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Old 13th August 2013, 18:24   #49
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Default Re: My TD to TDI VW Van (1990 model)

Your van is turning out to be really neat man. The seats in particular, look great. Where did you source them from?

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In my last posting I skipped lot of details., reason I felt like talking to my self.
That has to be one of the weirdest things that I've read on this forum in the recent past.
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Old 13th August 2013, 21:02   #50
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Your van is turning out to be really neat man. The seats in particular, look great. Where did you source them from?



That has to be one of the weirdest things that I've read on this forum in the recent past.

Thanks . Seats are from Innova.
This frank comment I like. Let me explain, for a car to fire it needs fuel, same way I need feed backs(any) like you from many more to fuel me to go forward.I want more question & I will try to satisfy. Thanks again AyAn
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Old 14th August 2013, 14:19   #51
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Default Re: My TD to TDI VW Van (1990 model)

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Originally Posted by narendra.vw View Post
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.
As per my past experience with Octavia, at speeds of 100kmph, the needle should be around 2000 rpm mark. And at 120kmph, it hardly reaches 3000 rpm mark.

Correct me if I am wrong. And if I'm right, what factors do you think are making this difference? And how do you plan to bring that down to below 3000 rpm? Can you please explain?
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Old 14th August 2013, 14:57   #52
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Default Re: My TD to TDI VW Van (1990 model)

It's exciting to see your van taking shape. Great work there!

Hope you would be able to clarify a few things, they are too noob-like though:
Quote:
Originally Posted by narendra.vw View Post
Tyre:- To tame the torque I have to up grade my 14” disc to 15”. 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...
Don't you think 3200rpm is a bit too high for the 1.9TDI? Is it because of a different final drive ratio/gear ratios compared to the Octavia?

Quote:
New air filter:- My air mass sensor is not accepting present air filter.
Why would the air filter affect the working of MAF sensor? Or, do you mean to say that your existing filter is clogged or suffocating the engine? You might want to get in touch with Arrowhead Filters if you are interested in a custom air filter for the van. I don't have any financial interest there, but I am a happy customer of theirs.
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Old 14th August 2013, 16:58   #53
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Default Re: My TD to TDI VW Van (1990 model)

Quote:
Originally Posted by silversteed View Post

Don't you think 3200rpm is a bit too high for the 1.9TDI? Is it because of a different final drive ratio/gear ratios compared to the Octavia?



Why would the air filter affect the working of MAF sensor? Or, do you mean to say that your existing filter is clogged or suffocating the engine? You might want to get in touch with Arrowhead Filters if you are interested in a custom air filter for the van. I don't have any financial interest there, but I am a happy customer of theirs.
Bare with me if I am late to respond. I can, only when I am back home. I am still desk top guy .
Thanks for your appreciation .

Regarding high rpm problem ,the OE gear box gear ratio of is on higher side., even 4h gear ratio is not bellow 1( Please refer to page 1). GB was basically designed for 1.6TD & also considering weight of the van app 2T & max speed was about 130 km/h . Additional 30 bhp of TDI is creating problem. Solution:-- 1) Upgrading tyre helps a bit. Maybe max 200 rpm
2) Changing Crown & pinion ratio. Available as OE . Have to be imported.
3) Changing higher 4 gear & 5 gear Available as OE . Have to be imported.

Right now I am enjoying the torque. Over taking, no calculation needed. Engine sound is the part, I didn't like at those speeds. Mileage , It should be around 10+/- 1 km/L at 100 to 120 km/h
I hope I have answered for you Madhav14 & silver steed.

TDI are very sensitive to air flow in take, which is monitored by MAS. MAS have heating coil inside where current flows through it. The air flow cools the coil this makes resistance of the current vary.
THE CURRENT is continually monitored by ECU in milliseconds with respect to it allows the fuel flow. Over cooling or less cooling will send wrong signal to ECU. Not much noticeable in engine performance . Check light come on .May be emission changes.
I my case its over cooling. I have ordered for new one.
K&N 57-0618-1 This model will soot any 1.9 or 2.0 TDI engines. Not available in India.
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Old 14th August 2013, 18:27   #54
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Default Re: My TD to TDI VW Van (1990 model)

HAPPY INDEPENDENCE DAY TO ALL MEMBERS & GUESTS
Tomorrow you all will be for along weekend, hence pr wishes.

Few more details I missed

Space was a prime factor, I had to use all my brain to minimize the length of intake.
I hate to see to many air ducts going around.

Following photos will explain.

Air filter to MAS adapter (Note a groove in side adapter is for O ring air sealing.
My TD to TDI VW Van (1990 model)-airfilter-adapter.jpg

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

My TD to TDI VW Van (1990 model)-ams-adapter.jpg

way to clamp it to the body
My TD to TDI VW Van (1990 model)-clamped.jpg
My TD to TDI VW Van (1990 model)-cimg1724.jpg

Engine lid hinged. hinges are from M 800 (I hate to find a place to keep the lid )

[ATTACH]1125213[/ATTACH
My TD to TDI VW Van (1990 model)-cimg1726.jpg
My TD to TDI VW Van (1990 model)-cimg1727.jpg

Gear box bedding fixed.
My TD to TDI VW Van (1990 model)-cimg1723.jpg
Name:  Gearbox_Bush fixed.jpg
Views: 1629
Size:  50.1 KB


Just for the knowledge Mini kitchen
My TD to TDI VW Van (1990 model)-mini.jpg
Attached Thumbnails
My TD to TDI VW Van (1990 model)-ams-top.jpg  

My TD to TDI VW Van (1990 model)-cimg1725.jpg  

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Old 14th August 2013, 20:01   #55
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Ho ho ho! I love that avatar pic of yours. Great sense of humour mate!
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Old 15th August 2013, 11:35   #56
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Default Re: My TD to TDI VW Van (1990 model)

Nice thread and amazing work! Wonder whether guy who sold will ever recognize and if at all he does, I don't want to contemplate what he will think
Hats off!
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Old 15th August 2013, 16:54   #57
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Default Re: My TD to TDI VW Van (1990 model)

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Ho ho ho! I love that avatar pic of yours. Great sense of humour mate!
You are very abservent , It can be easily mistaken as,“ name of a famous off-roader.”
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Old 15th August 2013, 19:03   #58
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Default Re: My TD to TDI VW Van (1990 model)

Most awaited work done today.

New wind shield fixed without any drama, thank to my well wishers .
Frankly, I was tensed . Replacing one more no way. Jay Ho

No rust inside edges
My TD to TDI VW Van (1990 model)-old-glass.jpg
Preparing
My TD to TDI VW Van (1990 model)-preparing.jpg
New glass fixed. Glass has to be cleaned I will do it later.
My TD to TDI VW Van (1990 model)-new-glass-fixed.jpg



NO one asked me how this INTERFACE works.

It can be used for any signal pluses adjusting work.
Wiring is simple & well instructed on top of it.. Left is for wiring ,center switches are used to on / off concerned signals, right two switches are used to increase or decrease the signals.

For speed adjustment, using GPS speed we can adjust Speed o reading in cluster. Once satisfied just lock the center switches.

Following Photo highlights my explanation
Name:  interface.jpg
Views: 1504
Size:  64.5 KB


Recently I got this OBD 2 pocket scan from my niece staying in US .( US mail)
I tried it on swift vdi, polo & Skoda & it works. They claim it works from 1996 to 2011. It’s good for beginners like me.
It only gives faulty codes( Including emission check.). we have to refer to code book provided & proceed in rectifying the problem.
Once done, we can erase check light with the same unit. Photo follows,
My TD to TDI VW Van (1990 model)-scanner.jpg
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Old 16th August 2013, 19:39   #59
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Default Re: My TD to TDI VW Van (1990 model)

How I converted van flooring into wooden flooring.

Leveling the floor with 2” wood bedding in the groove.
My TD to TDI VW Van (1990 model)-floor-leveling.jpg

One layer of ¼ “ plywood glued & nailed to the bedding.
My TD to TDI VW Van (1990 model)-floor-one-layer-playwood-sheet.jpg

One more layer of ¼” OSP glued on it
My TD to TDI VW Van (1990 model)-floor-one-layer-ost.jpg

Finally one coat of plastic coating & one coat of lacquer sprayed .
My TD to TDI VW Van (1990 model)-floor-polished.jpg


This should be helpful for Mahindra 4*4 owners

Sliding drawers development. ( Heavy duty sliders .No rattling )
Name:  different angle.jpg
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Size:  100.3 KB
My TD to TDI VW Van (1990 model)-drawer-painterd.jpg
Name:  drawer with seats.jpg
Views: 1430
Size:  71.8 KB


Just for the knowledge.
My mind always pushes me to make one rather then buy one
This GO cart was designed & fabricated by me in2002 for my daughter , forcibly taken away by my friend for his son’s birthday in 2004.
Details: Engine:---- 50cc kick starter TVS make.
Wheels & tyres:---Scooty
Brakes:---Drums, (Back two wheels, cable operated.)
Power:---Back right wheel. chain driven.
Highlight :- It had tie rod end for steering rod to absorb shocks( little bit)
Fuel tank::--Kerosene stove tank.
Fuel used:--petrol.
Seat:--Normal Domestic plastic seat legs removed.
Total Cost on those days:-- App 15,000/--

It used to run with three adults on it. My daughter used to power slide it.

This is a scanned photo. This is only photo I have.

My TD to TDI VW Van (1990 model)-my-creation.jpg

Next week if my budget permits I will be buying tyres. (Yokohama Geolandar AT-S G 012)

Last edited by narendra.vw : 16th August 2013 at 19:45.
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Old 16th August 2013, 21:40   #60
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Default Re: My TD to TDI VW Van (1990 model)

Wow! The wooden flooring turned out awesome!

Nice job there and great to see the level of commitment in restoration.

Waiting for the final product unveiling ceremony soon
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