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Diesel Swap Tech and FAQ / Re: How Far To Build Engine

« on: August 27, 2017, 08:57:35 am »

The 5 cyl gasser was undrivable, and I managed to get one that was running quite well.

Mine now has a VNT 17, 11mm pump and .205 nozzles, and I'm very happy with it. Just back from a road trip through the mountains and it consistently returned 30mpg. The gasser was 19-24 and the uphills were slow and loud.

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Diesel Swap Tech and FAQ / Re: How Far To Build Engine

« on: August 22, 2017, 12:07:25 pm »

You definitely want a VNT 17, and if your donor is a 1Z you want at least ALH pistons. If you're going to be flooring it a lot the bottom end will be under significant stress.

Get an EGT and manifold pressure gauge and watch for spikes and you'll be fine.

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Westfalia / Re: Pop-Top Weather Seal Options

« on: August 12, 2016, 11:08:48 am »

Yeah, it's broken in a few spots unfortunately.

I found the supplier that makes it but the "E-side" stripping isn't that popular and it looks like GoWesty isn't making much off it. What I'd really like to find is sliding door rubber seal now.

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Want to buy something? / Wanted: Green Tailgate and Black/Grey/Green Rear Bumper Cover

« on: August 09, 2016, 02:09:52 pm »

Our tailgate has a large dent from a previous owner and I'm finally looking at repairing it.
Also need the rear bumper covers, possibly only the corners. Ours are grey, but green or whatever would be fine too.

We're located in Phoenix, AZ, but we'll be in central California mid-september and then driving to Michigan in late September. If you're located between those places please let me know!

Thanks

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Interior! / Re: No backlight on cluster

« on: August 05, 2016, 03:44:47 pm »

Cable access is a little of both, there are multiple sections that connect together. One connection is in the engine bay near the firewall— on mine, this connection slid apart one day without unscrewing causing the speedometer to be erratic and then stop working. It wasn't fully disconnected, but the internal cable had stopped driving the next section.

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Interior! / Re: No backlight on cluster

« on: August 05, 2016, 01:11:31 pm »

No problem!

I just remembered another cause of no speedo/odometer: there is a small gear on the inside of the cluster speedo module (I want to saw a white or red worm gear) that can slip on its spindle. I had to simply push mine on more firmly to solve the problem.

I have a Passat electronic cluster now, though. If I get a chance and your cable seems fine I will try to find my old cluster and take a photo. Unfortunately the cluster has to come off for this, which requires removing the steering wheel and a 24mm deep socket.

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Interior! / Re: No backlight on cluster

« on: August 05, 2016, 12:25:47 pm »

The wiring diagrams are indispensable, but most other things you can mostly figure out yourself. Then again I don't have a gas engine anymore so that part is useless

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Interior! / Re: No backlight on cluster

« on: August 05, 2016, 12:09:55 pm »

let me go look at my Bentley and trace it back a minute.

L10 cluster lights get power on T28/12 (pin 12 of the cluster plug). That goes through U1/14 to what the Bentley calls terminal h1. H1 powers lots of things including the lights in the rear widow defogger switch, so you can check power on it by observing those lights.

H1 gets power from R/4, which gets power from pin 58b of "Light Switch". This pin supplies power from the dimmer wheel, which it gets from pin 58e, which comes from fuse 3 (10 amp).

So, get a cheap/free multimeter from harbor freight (or find/buy/make a test lamp) and verify power at those locations. When you find that, say, 58e has power but 58b doesn't, you know the thing in between (i.e. the dimmer wheel) is defective.

It's usually fuses or bulbs though

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Interior! / Re: No backlight on cluster

« on: August 05, 2016, 12:00:26 pm »

Speedo is probably a cable issue. There are a few joints where the internal cable can spin, and even get rounded off.

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Westfalia / Re: Pop-Top Weather Seal Options

« on: August 03, 2016, 03:14:13 pm »

Happen to have a link? I looked and didn't see anything. Ahh, I found it! I kept seeing the one for the Vanagon luggage rack. That looks like a pretty reasonable solution. Thanks!

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Westfalia / Pop-Top Weather Seal Options

« on: July 29, 2016, 03:16:53 pm »

The weather seal on our pop top is starting to separate and sag. Does anyone have experience with replacement options?

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Diesel Swap Tech and FAQ / Re: 1.9tdi vs 2.5tdi

« on: June 15, 2016, 10:56:16 pm »

I have not had the pleasure of driving a 5-cylinder TDI. While there is an extra cylinder for power, I'm not sure if it's needed or not. These are big vans and beyond a towing application, you're not going to find a transmission that can take advantage of the power off the line; it'll all be later on in second and third gears at least. Also the timing belt with the four-cylinder is so so easy compared to a Jetta or Passat-- so much room. Don't have to jack up or remove the passenger side wheel. Not missing the extra cylinder taking up space in that regard.

That said, I suspect that the major advantage to the five-cylinder is the overall engine balance. The original gasser (which is, I know, obviously not a diesel) vibrated the cabin a lot less. Fewer degrees between ignition events can only be a plus in this regard. I can make it up mountains just fine with my 1.9, VNT17, 11mm and .205 nozzles, but I find most of the time I'm just driving. Mostly I just want my two year old to go to sleep or to be able to hear the radio.

As far as parts go, I have ordered several things from European suppliers. Waiting weeks for them to arrive sucks sometimes. While I wouldn't anticipate needing a ton of hard engine parts, if you want to rely on the vehicle consistently maybe a two-week downtime (+£20 international post) is unacceptable.

If they run significantly smoother it is pretty tempting for my next one (down the line). Doing it for the weirdness factor is another perk (people around here already can't quite figure out what I'm driving). I only know of one 2.5l swap, so it'll be interesting to hear what others say.

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Westfalia / Re: Under-seat storage early/late

« on: June 06, 2016, 01:14:41 pm »

Approaching it from a problem-solving perspective leads me along this thought process:

• I (personally, others will be different) want to store clothes and maybe dry food.
• We'll probably access it most during pit-stops, after stopping for the night/in the morning, and maybe occasionally while going down the road
• If it's one big hinged flap, getting in there while stopped will require everyone else shuffling around. Making two or three sections hinge might mitigate this a bit
• If it's drawer(s), the same situation applies, but now we have added moving parts and vibration potential

I think I'd lean toward multiple hinged sections with the intention of adding cubbies behind (some of) them in the seat frame.

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Westfalia / Re: Under-seat storage early/late

« on: April 18, 2016, 01:12:52 pm »

Good to know. I just thought it'd be a good place to store clothes and such that you could get to without getting out and tracking mud in, etc.

I'm kinda wishing for a closet of some kind.

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Westfalia / Under-seat storage early/late

« on: April 17, 2016, 08:48:46 pm »

Does anyone know if the later under-seat cover (near where you pull to fold the bed out) can be retrofitted onto the earlier ('93) vans? The later ones look like they have drawers which would be very handy.

The early ones just clip to the rails under the seat, but I don't know how the later ones are attached.