mrj
Posted a lot
Posts: 1,662
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some progress on sunday : old engine loom out, coil pack and airbox in... after a bit of head scratching i managed to hang the Golf airbox on the right side of the engine bay; i just need a hose to the inlet manifold... the coil pack, the professionals take two in the bay, so they can switch over, when the coil dies; these are more prone to fail than the oldschool ones... ECU and relais will be placed under the rear seat, as the old one ...
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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Sept 25, 2011 7:16:55 GMT
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small progresss as life came in the way big time but yesterday i could do some more. Last week i was finishing the inlet manifold, but had to revise this, as the air flow meter was too far away from the inlet manifold, which could have made problems. So i used a K&N airbox adaptor to fit it properly : i also mad a CAD drawing, as i need another adaptor .... ;D a piece of plastic tube was added to the K&N part, to allow the hose to be fitted ... also a metal bracket was made, to bolt the airflow meter in the engine bay... so the air flow meter sits at the end of the factory hose, then the adaptor, air hose and airbox... here you see, why i need another adaptor; i'll be making that out of a sheet of pastic and another tube ... now i have a proper airfilter, and enough space to fit the expansion tank for the coolant; the type 25 has two of them ... so monday and tuesday we'll be finishing the conversion, as there is the last transporter meeting this yeaar at the next weekend ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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Sept 28, 2011 5:04:05 GMT
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cold air intake was also modified; i had to build another adapter for the air hose on the airbox... you might see, what i used ;D yesterday, after some smaller things left to do (fuel lines, water hoses etc.) the Bus was running; started first time . I did a longer test drive, it is really nice to drive. The exhaust note is a bit too loud for me , but the induction noise (or lack of) is ok, very quiet, no TÜV trouble for sure . Left to do for today : - change oil - modifiy dipstick - reverse light is not working - rev meter is not working - tighten up the hose clamps, replace one . and give it a darn good clean ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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Sept 28, 2011 5:55:10 GMT
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I just discovered this thread. It's a fantastic bus! Hope the 2.0 I4 sorts the problems for you. I've also been looking for a T3 Westfalia pop-top for a couple of months so far... Anybody selling one?
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Citroën DS 21 '66, Renault 16 TS '73, Scimitar GTE '74, Audi 80 '87, Merc 190E '88, Peugeot 205 GTI '88, BMW 735iL '89, Merc 230TE '89 , BMW 320i '92
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mrj
Posted a lot
Posts: 1,662
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Sept 28, 2011 18:54:54 GMT
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I just discovered this thread. It's a fantastic bus! Hope the 2.0 I4 sorts the problems for you. I've also been looking for a T3 Westfalia pop-top for a couple of months so far... Anybody selling one? the problem for you wouldn't be buying a Westi roof, but getting it up to Finland ? I have friends in northern germany, who might be able to help, it is a little closer to you. I wouldn't cut a hole in the roof of a transporter, i have to live with the huge hole the previous owner made on the engine; i have been driving it a lot today , and it grows more to me .... it is a bit new for me,as the torque/power delivery is different compared to the boxer; the boxer was ok on low-down torque and it really didn't make sense to go more than 5000 rpm; the new engine has the same amount of torque in a similar rpm region, but for power you really have to go above 3500 , which is ok, i just have to get used to it....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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one of the things on the to-do-list : the gear box mount; that was clearly tired and causing movement of the whole engine/gearbox and noises .... a new mount is 140 €, while you can buy a powerflex kit for 40 €, so this was the solution : ah wait, no ... ;D only pain was getting out the old one ; with a hammer , a saw blade and a hole it was done ... and fitted to the car again ... now it drives much better....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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Dec 31, 2011 12:25:34 GMT
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2,5 months later : i fitted winter tyres on ATIWE wheels, i didn't want to use the transporter over winter, but it drives just so nice , so i won't use it , when the salt is on the road, but since then ... they are ok in snow, but very skinny now this is my "new" exhaust : it is not finished now, as you can see. I have to add a flex pipe and fit a different crankshaft pulley (currently i have the one with power steering fittted, though i don't have PAS on this van) , so i can move it more upwards and fit it in the correct angle. This is the exhaust from the boxer engine, it is much quieter than the TD box fitted before; it sounds really nice. Very pleased with the result, it is now extremely reliable and lots of fun to drive....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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can't believe this is 4 months ago, since i posted in this thread Well, some progress : excuse the horrible pics, seems that the cam had a huge hangover that day ;D backbox removed, you see the two pulleys on the crankshaft and the waterpump, which would be necessary, if i had a power steering. I don't have it and i don't need it, so i removed them ... i also removed the oil filler neck, as the Golf engine has the filler in the valve cover... i built a blank plate to close the hole in the sump for the filler ... there is a cover available from VAG, i forgot to order that, but it was easily built from a metal plate ... done : repaired the exhaust bracket, nice to play with a proper welder. I made this in the company, as my welder died .... also i welded an extension to the dip stick, as the Golf dipstick was far too short... nice to know, how much oil you have in the engine ... bracket was modified , i used parts from the wbx back box and the Diesel exhaust ... now there is enough clearance : so i could move the backbox upwards , so that it sits even... now that looks really good, and sounds good , too . I tried to paint the exhaust with a special paint and it is working fine ... so, next things are some smaller things for the MOT and then i can have the engine registered to the papers .....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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ZXRob
Europe
Posts: 1,193
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Wow! I have just read the whole of your thread and I really love your van. When I was searching eBay for my van I saw quite a few that had the 2L conversion and it seems like a good way to get a reliable daily van. Keep up the good work.
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mrj
Posted a lot
Posts: 1,662
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Wow! I have just read the whole of your thread and I really love your van. When I was searching eBay for my van I saw quite a few that had the 2L conversion and it seems like a good way to get a reliable daily van. Keep up the good work. i have it for quite a few years, i started the thread in 2005, almost 7 years ago... a lot of things happenend, but the van is still there, and thats what i like about it . The 2L conversion is quite popular at the moment, as the Diesels are banned in most bigger cities in germany (and the tax is ridiculos for them) and most waterboxers are on their last legs, too. While the scrapyards are full of Mk.III Golfs and Passats with this engine ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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small update for mankind, but a big step for me ;D sorry about the curse word pics, I tried a new camera... anyone who drives/drove a T25 with a 5speed box knows that changing gears can be a challenge sometimes... as putting in 2nd or 4th resulted in switching of the radio I thought it was necessary, to refurbish everything : the gearstick from underneath... the rebuild-kit, still available from VW .... and rebuild... I also dropped the shortshifter kit which was installed, now shifting gears is like in a new car ;D whilst I was very busy at work, I managed to get a day off which lead me to a roadtrip : the TUV station, which is specialised on this type of conversion is in Trier, very close to Luxembourg . It is of course a bit of a trip, I could have tested the conversion here, but the TUV here is not familiar with this conversion, so a lot more of paperwork would have been necessary ... so I took the easy way and drove to someone who knows what they are doing . I also wanted to have my TUV (MOT) which was overdue since march .... well, the registration for the engine was no problems, whilst the bus failed the TUV. Upper wishbone bushes, which were fairly damaged ( I didn't see that before...) and some rusty brake lines .... not too bad, as I have 4 weeks time to make a re-test at any TUV station, so I didn't have to drive up there again .... so the weekend after the trip I replaced the upper wishbone bushes, cleaned and protected the brake lines, adjusted the front wheel bearings .... on Tuesday I went to the local test station and after 5 minutes : ;D and finally we went to a T25 meeting (the last two years I attended that meeting with the Passat... ) Happy end .... I know have Euro 2 emissions in the papers, they mentioned the original airbox in the papers, but not the exhaust... so I can build a proper one in the future ....
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Last Edit: Jun 7, 2012 7:45:49 GMT by mrj
- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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