PART TWO - ENGINE UPGRADE
Section II: PREPARING THE TDI ENGINE
As stated in the previous section, we have installed a TDI motor into my TriStar. However, I had two TDI motors sitting on my garage floor when we were doing the project:
We used the AHU engine into my TriStar for the simple reason of size. The AHU engine is about 2cm taller than the ALH motor which I will be now installing into my Syncro Westfalia Joker. With the ALH motor in the camper the engine cover will have a 'bump' that could be less than 2" tall. The TriStar has *lots* of room for a very tall motor, so size does count! The other reason for picking the better motor for the camper is that it is a lot heavier than the TriStar and I need every little bit of power that I can get on that Syncro!
Now that I have installed several I4 motors into Vanagons, it is a pretty quick procedure for getting the engine ready. The following is a quick 'play by play' of what is done. Times are approximate, I use air tools for my dismantling!
As I do not have to pass any emissions here in this section of British Columbia I will be removing the EGR system from the TDI motor as it does a great job of clogging up the intake system. If you decide to go this route, check with the local smog police before doing so.
Preparing the engine:
I have read accounts of intake manifold being totally plugged up from soot from the EGR system. This black tar is about as thick as peanut butter and is a real joy removing. I sprayed down the intake ports with Diesel and used a tooth brush and a shop-vac to remove all the crap, 95% of it anyhow! The #3 cylinder looks almost 50% blocked from soot - this cylinder is directly below the EGR valve. It is highly recommend from various sources to reduce the duty cycle of the EGR valve to the lowest setting using a 1551 or a VAG-COM. I am going one step further and removing the entire EGR system less the actual valve. It is important to note that you still have to leave the electronics and have a 'functioning' EGR system in place or else you will set off the check engine light.
© 2004 David Marshall