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You sir are doing exactly what I wanted to do day one with my CQ. I wish it were easier/cheaper to import the 2.5 TDI engine, especially the one from the Crafter- same design but with common-rail management. :) Good luck and I'll be watching this one closely.

To the others out there, don't underestimate the power potential of the 2.5 TDI. 300hp is easy without even cracking the engine open, and the amount of torque at that level would be enough to pull a house down. :D

Brendan
 

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Discussion Starter · #23 ·
More progress, moved onto the interior and harness swap.
After looking at the harness for several hours (minutes) it was clear that the proper way to install it is to remove the dash and HVAC, since I had to remove the pedal cluster anyway (more on this later) it was a no brainer.

What was a brainer was the PITA to remove the HVAC... that is one serious assembly... doh!

Here is the emptyness it left.



And here it is released into the wild.



I decided to change the heater core while it was out, however not sure replacing a stock German part with 150,000 km on it with a Made in China part is any better, time will tell.

Next came the pedal box...
Here it is..



Oops, I lost it..



Naah.. here it is.. poor little thing.. it's going to be made into a Honda or Toyota.. :( Unless someone wants one to mount on the wall.



And here is why the TDI pedals are different. The TPS sensor is mounted on the pedal box itself.. no throttle cable here.
This little gem is on it's way across the pond as I type this..




Looks like the clutch is at the post office, Mr. Cook will help out and supervise the welding of the motor mounts, and hopefully next week she'll be in there nice and comfortable.

One thing I don't have yet is the rad fan shroud, anyone have a plastic stock unit? I might splurge and get the RS2 unit, only if I can't find a stock one though.

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Discussion Starter · #25 ·
Moral support always welcome.

Hoping to have the engine/tranny in early next week.

Clutch arrived today and I am picking up the flywheel tomorrow.. it's a special gem, has 5 window casting in the back for the computer to read timing.

Here is the original for 016 gearbox.



The ABP and AAT also use the 5- window reference casting but have built in pilot bearing portion to allow use of 01E.



Notice the dish? Diesels like heavy flywheels.. ;)

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It's like pioneer DBW setup! :)

Martin, I have a stock 7A fan shroud you can have, just pay for shipping. PM me your addrss, although I might already have it from the past, and I'll send it out. When FedEx charges me I'll let you know exactly how much it was.
 

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Discussion Starter · #28 ·
Thanks Peter, I'll PM you.

Only other thing I still need to figure out is how to by-pass the stock fuel pump.
TDI does not use a fuel pump, it's pure suction via the injection pump so I need to remove the pump out of the system (including stock fuel filter) and still have it work properly when the tank gets low on fuel.

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Discussion Starter · #30 ·
Does anyone know if the electric vacuum pump from a B6 A4 would provide enough vacuum to power the booster.
I know it's there as a supplement, but not sure if it can do the job by itself.
That's another part I will have to sort out... the list is growing.

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ralleyquattro said:
Only other thing I still need to figure out is how to by-pass the stock fuel pump.
TDI does not use a fuel pump, it's pure suction via the injection pump so I need to remove the pump out of the system (including stock fuel filter) and still have it work properly when the tank gets low on fuel.

Cheers
I'd see if you can retrofit a PD in-tank lift pump. (or some other low-pressure pump) The wiring would already be there, and having an electric pump on a TDI will really make changing fuel filters a lot easier. :) Adding an electric pump was one of the best things I did on the Golf Diesel build.

Brendan
 

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How about just using the stock pump/wiring and a fuel pressure regulator to reg it down to 6psi or so. This is what i have in mind for gasser turned tdi car. Don't have the regulator figured out exactly but that's what i'll attempt. It will add to your fueling potential too-when you decide to turn it up! ;-)
Love the project!
 

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Discussion Starter · #33 ·
Thanks for the tip, looked into it and yes, actually having the pump in there is beneficial in many ways.
Just need to figure out the best way to drop the pressure.
Also wondering if the stock fuel filter will like diesel going through it... never hurts having two filters.. ;)

Here is more.

Mr. Cook came by on Saturday and helped me withe the motor mounts.







I think I screwed up the driver side a bit, but nothing that a shim/spacer won't fix.

Picked up the flywheel and engine hoist today, hope to have the transmission and rest of the wiring in tomorrow and possibly the enigne itself... we'll see how the weather holds up.. it's HOT HOT HOT out there... we haven't had any rain in over 3 weeks, the grass is deed..

Anyhoo.. few more questions, any suggestions on electric vacuum pumps on a budget. I looked at the B6 and Passat pumps but don't know if they are supplemental or actually provide full vacuum to the booster, anyone know? They are only $100 and would match the OEM better than some aftermarket Jegs unit.

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It's same in Chicago here...high of 37*c in the shade! That's 97*f I think.

I saw that last picture and thought that driver's side mount looks a little high on the back end?

Martin, any way to find out how much vacuum those new OEM pumps are pulling? Otherwise, Summit sells vacuum pumps that many hot rodders use - I've looked at them when I was setting up ITBs, but it turned out that I had just enough vacuum on the brakes...it wasn't bad at all. So I think you don't need too much vacuum.
 

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Discussion Starter · #39 ·
a_CQ said:
It's same in Chicago here...high of 37*c in the shade! That's 97*f I think.

I saw that last picture and thought that driver's side mount looks a little high on the back end?

Martin, any way to find out how much vacuum those new OEM pumps are pulling? Otherwise, Summit sells vacuum pumps that many hot rodders use - I've looked at them when I was setting up ITBs, but it turned out that I had just enough vacuum on the brakes...it wasn't bad at all. So I think you don't need too much vacuum.
Actually it's the other way around, the front end of that mount is a bit low...

I've looked at the hot rod pumps as well, but they are $300/kit almost anywhere and I rather spend $100 on an OEM unit if it works.
Anyone has one of these B6 pumps lying around and willing to test how much vacuum it can pull?

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ralleyquattro said:
Anyhoo.. few more questions, any suggestions on electric vacuum pumps on a budget. I looked at the B6 and Passat pumps but don't know if they are supplemental or actually provide full vacuum to the booster, anyone know? They are only $100 and would match the OEM better than some aftermarket Jegs unit.

Cheers
Don't know about the B6 vac pumps, there is this option as well for about the same price:
http://www.accuratediesel.com/shop/132.html

Might be a good idea with either option to grab an OEM vac reservoir (inner fender mount maybe?) just to be sure.

Pity there is not a provision for the ALH style vac pump off the cam, or the distributor mounted one like the old 1.6 diesels had.

Brendan
 
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