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AFN TDI install

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syncroandy View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote syncroandy Quote  Post ReplyReply Direct Link To This Post Posted: 09 Apr 12 at 21:44
Originally posted by max and caddy max and caddy wrote:

Heyup!! is the pump spitting diesel out the ruturn pipe when cranking? if yes lift pump is ok...if no its most likely just not primed up yet...


Now then chap. Can't see as I'm up front on the key, another pair of eyes would be good.

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solenoid click test is non conclusive but most likely itsĀ ok...does your FAGCOM have a "final control diagnosis" or actuator test function? if so you can switch with the ecu to test the output..


Output tests in VCDS seem to do nowt for the cutoff solenoid. Bid of a headscratcher..
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got any easy start?


Heh, just had a poke about in the workshop and found a vintage can.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote syncroandy Quote  Post ReplyReply Direct Link To This Post Posted: 10 Apr 12 at 08:59




TBH feel a bit of a numpty I didn't try this before bleating on here ! An essential item. Patched in a temp wire to the starter so I could spin it whilst squirting the EZ start.

Also confirmed the fuel shutoff solenoid is only opened by the ECU when it sees the engine cranking.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote syncroandy Quote  Post ReplyReply Direct Link To This Post Posted: 11 Apr 12 at 21:57
Finished the spannering today, having fitted prop and driveshafts, fabbed a bracket for the pedal sender, re-fitted exhaust including making a couple of new brackets. Yesterday whilst running the engine noticed a couple of issues that'll need attention, an air leak into the fuel inlet, and a bit of oil weeping out somewhere around the filter. Sadly the turbo does seem to be spitting out a small amount of oil at startup (noticed this before I fitted the exhaust) it remains to be seen how much of an issue this is. Tomorrow I'll chuck the harness on (temporary until I can do a tidy job) and try and sort the above issues. Engine now looks like this:
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Post Options Post Options   Thanks (0) Thanks(0)   Quote max and caddy Quote  Post ReplyReply Direct Link To This Post Posted: 11 Apr 12 at 23:30
Tidy...found what i thought was my rear main leaking is in fact the crank sender leaking...could be the same on yours as it seems to be in the same spot...maybe..
 
 
whens MOT day?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote syncroandy Quote  Post ReplyReply Direct Link To This Post Posted: 12 Apr 12 at 07:54
Tomoz unless I phone to cancel..

Ordered a new fuel filter and thermo valve yesterday lunchtime from BW but it didn't ship so may have to get another from local motor factor as I suspect the o-ring, and if I'm messing with it to investigate the leak I may as well renew it.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote syncroandy Quote  Post ReplyReply Direct Link To This Post Posted: 13 Apr 12 at 18:55
Right, its all done, test driven, MOT'ed and taxed. The AFN makes a huge difference to the driveabiity of the Syncro. I'm shattered though, so will get an early night and drive down to the Shipston Syncro event early tomorrow instead of tonight. Be a much nicer drive as well.

Worked on the wiring till 11 last night, and got up at 5 this morning to finish it off and get the van back to a drivable state for the MOT which I put back to 3pm. The local place in Melling is very friendly, run by a young couple who happen to run a Bay.

Didn't really encounter any significant problems. Timing was well out unsurprisingly, resulting in clouds of white smoke, but this was quickly resolved by moving the pump toward the block pretty much as far as it'll go. Thanks to Ewen for advice on this. Air leak into fuel seems to have gone away, I just replaced the bit of hose on the end of the inlet pipe.

Chargecooler circuit was a bit slow to fill, took a few goes at topping up but once all airlocks had cleared the Merc pump seems to be working much better than the old VW coolant pump. I'll keep an eye on inlet air temps with VCDS.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote lloydy Quote  Post ReplyReply Direct Link To This Post Posted: 13 Apr 12 at 19:10
Congrats! Wish i could be at shipston to see it. have a good weekend.
Picking mine up on the 28th
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ninja.turtle007 Quote  Post ReplyReply Direct Link To This Post Posted: 13 Apr 12 at 19:22
Well done Andy.

I know you Subaru is very quiet but how does the TDI compare?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote syncroandy Quote  Post ReplyReply Direct Link To This Post Posted: 16 Apr 12 at 09:11
Right, back home now after the ~360miles round trip to Shipston, engine performed faultlessly though I still need to do the timing properly. Gearing seems fine for my needs, not too high so will accelerate and climb hills OK, but with enough headroom to woosh past trucks on the M-way.

Inlet air temps ranged from 30-40 celcius whilst cruising and including some full throttle overtaking on the M-way, which I think is very good. Will be a bit more on hot summers days, but should still be acceptable.

Really happy with overall smoothness and level of Syncro vibes. The main source of NVH is just the MT tyres which I have to accept. I didn't take any particular trouble with alignment, just bolted the engine/box in as normal and it's fine. Did check and re-grease the rear CVJ's.

There was a slight possibility that modifying the stock JX rubber mount position might compromise the engine mounting adversely, but I've not noticed any detrimental effects so far. TBH I can't see the point in bothering with the hydro mounts, the JX ones seem fine to me. The AFN seems much smoother than the old 1.6. Should be nicely balanced as injectors were all setup by a diesel specialist, and I fitted a new harmonic balancer (found a cheap NOS one at a show).


Edited by syncroandy - 16 Apr 12 at 09:16
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ewenmaclean Quote  Post ReplyReply Direct Link To This Post Posted: 16 Apr 12 at 16:28
Hi Andy,

this is great work - the engine mounts look excellent and the chargecooler setup - some serious thought's gone into all of this.

As far as the N75 vs N18 goes they are very slightly different internally in springs and dampers - I think the only difference is part number is the N75 has an A at the end - 1H0 906 627 for the N18, 1H0 906 627A for the N75. The N18 won't work as well and you won't get as much boost but is good as an emergency replacement. The reservoir and check valve aren't vital but I've read it's there so that if in some strange scenario you use the brakes heavily and then need the turbo to spool quickly it has a backup vacuum source - I left the original res ball on mine but haven't experimented with removing it.

Lee seems to have cleverly figured out how to reclock the turbo to vertical, but repositioning the actuator might be tricky with the AFN exhaust manifold. I do get a bit of oil past the seals on mine if it's been sat for a while, but it goes away once it starts boosting. You can get kits with 360 thrust bearings for the VNT15 - this is supposed to help keeping the shaft well balanced but I've not done that on mine. My oil consumption seems to be ok - the mod I had been playing with as I told you I think was retrofitting an anti-shudder valve since runaway is a bit of a worry if the turbo seals aren't doing their job properly on the compressor side, also with a PCV setup designed for a vertical install I'm still unclear on how much oil vapour is really going through the turbo.

Thanks for the pictures and update - hope all the remaining jobs get sorted out easily.

Ewen


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Post Options Post Options   Thanks (0) Thanks(0)   Quote t'onion Quote  Post ReplyReply Direct Link To This Post Posted: 16 Apr 12 at 17:23
Cracking work Andy Clap
I had a look at Jed's the other weekend , sounded sweet as a nut ( well done Russel )
Fancy putting one into my LT ? Ouch
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Post Options Post Options   Thanks (0) Thanks(0)   Quote syncroandy Quote  Post ReplyReply Direct Link To This Post Posted: 18 Apr 12 at 18:22
Cheers Mark ! Saw a nice 2.4TD intercooled in a local scrapper the other day in a Volvo estate, but I guess a 2.5TDI is the way to go for an LT ?

Right, done the timing properly now using VCDS, and set it to just toward the advanced side of the middle setting. The run to and from Shipston seemed to have used more fuel when I expected (running retarded), and on the way back I plugged in my Scanguage and was seeing typical fuel consumption of ~15 litres per hour cruising, which is not very good. I'm now seeing ~10-12, which is encouraging, but I've yet to work out any proper figures.

The Scanguage is a great bit of kit, it has trip computer capability a bit like the VW MFA, and you can also input fuel data when you fill-up, and get miles to empty, time to empty etc. For real-time data, you can display 4 parameters at once, eg. inlet air temp, throttle position, fuel consumption etc etc. To get the best from it you need a VSS, and that's next on my list, will pay a call to the scrapper tomorrow and see if they have any Mk2 Golf GTi clusters with the hall sender fitted.



A few notes on things I've mentioned before. The turbo seems not to have been seeping oil noticeably since the first run, I'd had it apart for cleaning, and suspect it needed to run for the seals to seat properly. No nasty oily smells or blue smoke anyway.

The oil leak on the pump side was from the breather pipe, I'd used the two-part one, and it was leaking at the o-ring, until I can get a better part I've just sealed it with silicone.

I do have some oil now on the block on the turbo side, I've not looked closely yet, but this is probably from the cam cover gasket. This engine had the cam cover with seal bonded to it, so I couldn't renew it. Any comments on this welcomed. Shall I just re-seal with silicone, or should I try and find a cover with separate seal, as I have a fresh seal that came in the Elring kit I bought ?

The tacho is over-reading by about 30%, but I'm using a solid alt pulley and want to try and find a clutched one of suitable diameter and offset. Will leave adjusting the tacho (screw on the back) until I've sorted the pulley. Although I'm using an AAZ alt (W and D+ connections), and the ECU is from a 99 Passat that had a DF connection on its alt, I'm not getting any DTC about the missing DF signal, which is nice.

Oh yeah, forgot to mention how nice it is to hear the turbo spooling up from tickover until it goes supersonic !

Edited by syncroandy - 18 Apr 12 at 18:36
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Post Options Post Options   Thanks (0) Thanks(0)   Quote max and caddy Quote  Post ReplyReply Direct Link To This Post Posted: 18 Apr 12 at 18:31
All well and good but...when you taking me for a blast in the country in it?

Edited by max and caddy - 18 Apr 12 at 18:34
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Post Options Post Options   Thanks (0) Thanks(0)   Quote niko Quote  Post ReplyReply Direct Link To This Post Posted: 18 Apr 12 at 19:29
Agree about the turbo spooling up......
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Post Options Post Options   Thanks (0) Thanks(0)   Quote jed the spread Quote  Post ReplyReply Direct Link To This Post Posted: 18 Apr 12 at 21:27
Good work Andy Clap

Please give it a go with some A/Ts on Wink When I first took my Mrs out in ours she thought it was smoother than her dads Petrol Merc LOL

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Post Options Post Options   Thanks (0) Thanks(0)   Quote VW Nerd Quote  Post ReplyReply Direct Link To This Post Posted: 19 Apr 12 at 09:42
The std VW vss from the early golf speedo or T3 speedo does not send a true road speed to the ecu. In fact it will only show half of true road speed, but will get rid of associated fault code.

You can buy a new item from a guy in Germany, built for TDI conversion and fitting into the back of speedo.

The ecu is looking for 4 pulses per wheel revolution.


Edited by VW Nerd - 27 Jan 13 at 22:31
Developing parts for the VW T3 TDI market Inc flipped audi gearbox install parts.

Tim Shettle
www.ultimate-engineering.co.uk
Bristol

Tel/txt 07810 320 464

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Post Options Post Options   Thanks (0) Thanks(0)   Quote max and caddy Quote  Post ReplyReply Direct Link To This Post Posted: 19 Apr 12 at 11:03
Originally posted by VW Nerd VW Nerd wrote:

The std VW vss from golf/T3 does not send a true road speed to the ecu. In fact it will only show half of true road speed, but will get rid of associated fault code.

You can buy a new item from a guy in Germany, built for TDI conversion and fitting into the back of speedo.
but will it work the CCS?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote syncroandy Quote  Post ReplyReply Direct Link To This Post Posted: 19 Apr 12 at 13:59
Tim, don't forget the Syncro speedo is 1000rev/km vs the 500rev/km of the 2WD, so I hope the normal hall sender may work. Watch this space.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote syncroandy Quote  Post ReplyReply Direct Link To This Post Posted: 19 Apr 12 at 20:59
Yep, fitted a Mk2 Golf 3-pin sender pn. 321 907 345 A, and TDI ECU seems happy with that. Vehicle speed seen by the ECU is a bit under the actual speed seen by GPS, but the ECU has a compensation factor which I'll have a play with. Next up will be CCS !
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Post Options Post Options   Thanks (0) Thanks(0)   Quote syncroandy Quote  Post ReplyReply Direct Link To This Post Posted: 20 Apr 12 at 19:15
Right, CCS is done. A while back I'd found a NOS stalk off a Golf or summat which is near enough, had to trim a tiny bit off the cowl for clearance. Length is fine with the 'velle steering wheel.

Some headscratching was involved, as I'm using a 99 ECU, and early CCS stalk. The 99 CCS stalk has an additional switch position and one more pin. I found I had to common the 'spare' ECU connection onto one of the other ones to make the ECU see the CCS as being switched on. I can forward details if anyone needs them.
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