[Machado]

Heart warming to see the love you have for VW Van. Once classic piece this is. Great job till now

[crdi]

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!

[madhav14]

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.

[coloneljasi]

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.

[narendra.vw]

Originally Posted by crdi

. 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.

Originally Posted by madhav14

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.

[madhav14]

Originally Posted by narendra.vw

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.

[narendra.vw]

Originally Posted by coloneljasi

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.

[coloneljasi]

Originally Posted by narendra.vw

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.

[narendra.vw]

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.



Speed sensor of TDI getting ready to mate with TD cable.



speed interface used to recalibrate and send right signal to the cluster.. USA make.


Location of interface & speed sensor.


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.



Acc pedal. I didn’t 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.




Tail lamp wiring.

Tail lamp when it’s lit.


sun visor . 1990 they think of this & still works. Happiest person, my wife for this.




Centre row lighting.


Photo taken without flash.


Front blower knob (Hot air only) extreme right.. Rest is for AC control.



Using two alternators one for the van battery other for charging acc battery . Acc battery will be used for ? Later.


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.



Contact points.



Left is for my bosch horn ( been with me for over 20 yrs.) right is for sliding door catcher opening.
Bottom centre, unique. It’s 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.



Back passenger hand rest with door catcher switch.



Just for the knowledge. vacuum layout


Next time I will back with air supply .

[narendra.vw]

Air intake route details.

Air mass sensor

air filter to turbo hose

starting of air filter

ends at turbo

firmly clamped


inter cooler to be fitted.

Inter cooler

inlet hose

Route of air intake

turbo to inter cooler

turbo out

To inter cooler

Inter cooler to inlet

complete


Exhaust


fitted to the engine



Just for knowledge I love to fabricate such a body jack

[narendra.vw]

flooring finished

roof ac fixed

middle seats

back row seats

space utility

jail bar protection for back glass

bedding for gear box


ac working. just for knowledge


Thanks for all of you who had shown keen interest, viewed & Replied this thread.

[ambivalent_98]

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.

[spawnofsatan]

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!!

[narendra.vw]

Originally Posted by spawnofsatan

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

[narendra.vw]

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 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.

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 it’s 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 15” 5hole 112 pcd
TYRE:-- 205/ 15”/ 70 A/T.

I will be back with photos & details.