1987 Syncro Westfalia
Pix of Sunny's
Vanagon/TDI Conversion
| Done so far (Oct, 2001): | |
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Installed heavy-duty clutch |
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Installed Syncro TD fuel tank |
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Installed HA Projekt wiring interface between TDI and Vanagon wiring harnesses |
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Installed HA Projekt potentiometer kit to Vanagon accellerator pedal |
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Modified fuel inlet to accomodate wider diesel fuel pump necks |
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Locking transmission rebuilt by Weddle with custom 1.19 3rd & 0.70 4th gears |
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Custom Stainless-steel exhaust |
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Custom hydraulic hose from Vanagon power-steering rack to TDI power-steering pump |
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Custom fabricated air/water radiator for Spearco air/water intercooler (see image below) |
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Installed snowmobile fuel injection hose for diesel fuel delivery -- remains flexible down to -40F |
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New water pump/hydraulic belt, serpentine belt, and timing belt |
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Plumbed air/water intercooler and air/water radiator |
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Hooked up R134 Air Conditioner with all new lines |
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Finished wiring!! (still needs to be prettied up) |
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Pipercross air filter behind left rear brakelight |
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Upsolute low-smoke chip for 110hp and 175ft lbs torque |
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Installed additional VDO gauges i.e. oil pressure, oil temp, voltage, exhaust pyrometer, turbo boost |
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Finally, added the TDI logo to the front, rear, and insides of my Van! |
Other features: |
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Custom Bilstein shocks |
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Custom Betts Springs |
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Air Lift kit for rear shocks |
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Cross-drilled brake disks (thinking of installing 15" South African "big brake" kit instead) |
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Custom 2" hitch |
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10' Fiamma F45 awning |
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Custom fibreglas dash (painted yellow) to hold gauges |
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Custom remote oil cooler & Amsoil dual bypass oil filter. Click here for a photo |
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15" alloy rims with 235/75-15 AT tires |
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New South African radiator |
Other yet to do: |
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Install new 3-way tent from Bus Depot |
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Install sound-proofing in engine compartment |
Links: |
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Why I am installing a TDI engine in my Vanagon |
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HA Projekt wiring Interface (PDF) |
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HA Projekt potentiometer mounting instructions (PDF) |
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Industrial TDI engine (PDF) |
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Industrial TDI Wiring Diagrams: page 7, pages 8-10, page 11 |
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TDI diagnostics (PDF) |
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TDI specs (PDF) |
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VW Diesel Engine pulleys (PDF) |
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TDI Engine CAD drawings (PDF) |
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TDI Electronic Diagnostics |
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Diagrams of air/water intercooler system (PDF) |
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Complete 1996/1997 Jetta/Vento TDI Wiring Diagram (373k PDF) |
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Jetta TDI ECU pins spreadsheet 1997 (20k XLS) and HTML version |
External links: |
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Tom's Vanagon Engine Conversion |
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Fred's TDI Page |
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VW Vortex |
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HA Projekt (German) |
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TDI Conversion list |
Thanx: |
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Dennis Gagnon of Amesbury Foreign Auto in Amesbury MA |
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Frank Grunthaner and Dave Bayer from the Vanagon List |
Comments to: michael@haywood-sullivan.com