AAZ Vanagon Injection Pump Lever

October 25, 2014

Background: We’re putting a 1.9 liter AAZ turbodiesel into a stock ’82 diesel Vanagon, which came from the factory with a 1.6 liter naturally aspirated diesel.  Because of the extra height of the 1.9 block and the orientation of the lever, it is too tall for the engine compartment.  The stock 1.6 Vanagon diesel injection pump lever is bent to fit under the lid, here’s a comparison showing the stock pump on the left:

IMG_2348

Brickwerks in the UK makes a bolt-on solution, but they don’t ship to the US:

aaz lever2

Although the 1.6 lever has the same diameter, the mounting post on the AAZ is taller, so the lower spring and carrier from the 1.6 stock pump won’t fit. In addition, with the AAZ lower spring installed the 1.6 lever won’t engage the splines (1.6 splines sit on top of the lever, on the AAZ they sit below the lever).

IMG_2371

So, a hybrid lever might be the solution. Here you can see the lower plate from the AAZ engages the splines, but the bend in the 1.6 lever is a bit too close to fit.

Also, the spring will require the damping plate from the AAZ sandwiched in-between the 1.6 and lower AAZ lever, as right now there is no spring connection on the lever to return the throttle back to idle.

IMG_2380

Looks like I’ll have to either grind the AAZ plate down so I lose the second bolt hole, or fabricate a new arm to bolt into the AAZ lower throttle plate.  Decisions, decisions…


Mat-Su College Biodiesel Class October 2014

August 28, 2014

VanniepooSorry for missing everyone at the 10th Annual Renewable Energy Fair, but we spent our summer veggin’ around the state of Alaska in our 1982 Vegoil-converted VW Vanagon Westfalia – lots of fun with cost-free carbon-free fuel!

Once again, UAA Mat-Su College is offering a BASICS OF BIODIESEL AND VEGETABLE OIL FUEL SYSTEMS course for one credit in the University of Alaska System this October, 2013.

Make your own biodiesel, design a SVO-fuel system for your diesel vehicle, investigate Alaskan vegetable-oil heating options.  Proper lab techniques, basic vegetable oil chemistry and appropriate vehicles for conversion will all be covered.

Classes will be held at Mat-Su College, off Trunk Road about a mile north of the Parks Highway, past Mat-Su Regional Hospital.

We will hold FIVE 3-hour Classes on Wednesdays: October 1, 8, 15, 22, 29 from 5:00-8:00pm.

Register directly through Mat-Su College at matsu.alaska.edu. Course# RE A194F

Call the college at 907-745-9746 or instructor Will Taygan at 907-688-5288 for more information.

Full disclosure: I’ll be teaching this class. Veg On!


Mat-Su College Biodiesel Class October 2013

August 29, 2013

UAA Mat-Su College is offering a BASICS OF BIODIESEL AND VEGETABLE OIL FUEL SYSTEMS course for one credit in the University of Alaska System this October, 2013.

Make your own biodiesel, design a SVO-fuel system for your diesel vehicle, investigate Alaskan vegetable-oil heating options.  Proper lab techniques, basic vegetable oil chemistry and appropriate vehicles for conversion will all be covered.

Classes will be held at Mat-Su College, off Trunk Road about a mile north of the Parks Highway, past Mat-Su Regional Hospital.

We will hold FIVE 3-hour Classes on Wednesdays: October 2, 9, 16, 23, 30 from 5:00-8:00pm.

Register directly through Mat-Su College at matsu.alaska.edu. Course# RE A194F

Call the college at 907-745-9746 or instructor Will Taygan at 907-688-5288 for more information.

Full disclosure: I’ll be teaching this class. Veg On!


9th Annual Alaska Renewable Energy Fair – Sat Aug 10th, Anchorage!

August 7, 2013

BIODIESEL SEMINAR 1PM THIS SATURDAY, AUG 10TH!

9th Annual Alaska Renewable Energy Fair
Saturday, August 10th | 11:00 am to 9:00 pm
Downtown Anchorage Parkstrip

This event is fun for the whole family! Come enjoy local food and craft vendors, DIY demonstrations, informational booths, a text to win energy scavenger hunt, all new children’s activities, and 20 clean energy workshops. Admission is FREE and it’s guaranteed to be a great time!

Workshop topics include:
AK SeaLife Center Heat Pumps
Wind Power on the Railbelt
Cook Inlet Tidal Power
Easy Energy Efficiency Home Improvements
And MORE!

Also enjoy ice-cold Alaskan Microbrews in the beer garden, and hear live music from bands like the Super Saturated Sugar Strings, Tim Easton w/ Megan Palmer, and the Aloha Bluegrass Band.

See more at: http://alaskarenewableenergy.org/


Anchorage Renewable Energy Fair, Sat Aug 11, 2012.

August 2, 2012

Renewable Fair 2012

Join REAP for the 8th annual Alaska Renewable Energy Fair on Saturday, August 11th from 11:00 am to 9:00 pm on the Anchorage downtown parkstrip between I & E Street. Admission is FREE, and it’s guaranteed to be fun for the whole family! Enjoy the live music, a beer garden, great food, kids activities, informational booths, and renewable energy workshops.  Includes a 4pm Biodiesel workshop, SVO converted Volkswagen Westfalia, SVO converted school bus and more veggie goodness!


VW Vanagon Inline-4 TiiCo/Remtec Transmission Adapter Plate and Flywheel

April 28, 2012

Post #4 in the TiiCo dismantling saga, the TiiCo/Remtec/diesel transmission adapter plate and flywheel. (Remtec was Volkswagen of South Africa’s engine rebuilding division – now a separate entity.)

I’ve read that the flywheel is customized to mate a 1.6(1.9?) diesel or 1.8/2.0 gas engine to the standard gas VW Volkswagon Vanagon transmission with the 228mm clutch. (This one connected a 2.0 3A Audi bubble block to a VW syncro transmission.)

The Tiico transmission adapter plate mounts between the engine and the flywheel and allows the inline-4 engine to be mounted at a 50 degree angle to fit under the Vanagon T3 Transporter deck lid.

Flywheel: stamped 223674 on back, scratched 51 on the hub in the inside, no VW part numbers.

Transmission Adapter Plate: marked 996-100-001BX, but this seems to be a number for an entire remanufactured Remtec (TiiCo) 2.0l inline-4 Vanagon (Kombi/Transporter) engine.

More TiiCo info:
Vanagon TiiCo Dual Output Exhaust Manifold
Upgraded Vanagon TiiCo a3 Mk3 Intake Manifold
Vanagon TiiCo-Diesel Coolant Hoses


VW Vanagon Inline-4 TiiCo/Diesel Coolant Hoses – Engine Compartment

April 27, 2012

Tearing apart this TiiCo engine has let me confirm that the three complicated TiiCo hoses (shown) *are* the same as the late-1.6 CS diesel and 1.7 KY Vanagon T3 Transporter diesel hoses (and two hoses are the same as the 1.6 turbodiesel JX engine).

Only the bypass hose from the head to water pump (not shown) is different. Note that the bypass hose is not Vanagon-specific and therefore common and cheap for both gas and diesel engines.

For more details about the hoses and engine codes (note DH is 1.9l 83-85 gas) see an earlier Arctic Vegwerks post: Diesel VW Vanagon T3 Coolant Hoses Engine Compartment.

Van-Cafe has the Tiico Engine Conversion Hose Kit for $295 in standard rubber and Justin at Greaseworks sells the colorful upgraded Diesel Vanagon Silicone Hose Set w/clamps for $399. Notice Van-Cafe’s gas bypass hose is S-shaped, while Greaseworks’ diesel bypass hose is more L-shaped.

You can also see where the PO cut the ends of the hoses to remove them from the underbody coolant pipes.

(3) Lower 3-Way Hose (Return) From Radiator Pipe & Oil Cooler to Water Pump
late-CS+KY+TiiCo 068-121-073G

(6) Lower 3-Way Hose (Return) From Front Heater Core Hose to Water Pump & Expansion Tank
late-CS+KY+TiiCo+JX 068-121-081C

(17) Upper “Octopus Hose” 4-Way Hose Feed From Block to Radiator, Oil Cooler & Expansion Tank
late-CS+KY+TiiCo+JX 068-121-101H

Coolant Pressure Expansion Tank
late-CS+KY+TiiCo+DH 025-121-407

Coolant Pressure Expansion Tank Low Level Sender
late-CS+KY+TiiCo+DH 251-919-372

More TiiCo info:
Vanagon TiiCo Dual Output Exhaust Manifold
Upgraded Vanagon TiiCo a3 Mk3 Intake Manifold
Vanagon TiiCo Transmission Adapter Plate


VW Vanagon Inline-4 TiiCo 6 bolt Dual Output Exhaust Manifold

April 26, 2012

VW Volkswagen Vanagon TiiCo Post #2. Here’s the dual output 6-bolt cast exhaust manifold – no O2 sensor. I know it fits 1.8 gas and 1.6 diesel heads, perhaps more? Manifold is stamped ROH 1HS-253-033B.

More TiiCo info:
Vanagon TiiCo-Diesel Coolant Hoses
Upgraded Vanagon TiiCo a3 Mk3 Intake Manifold
Vanagon TiiCo Transmission Adapter Plate


VW Vanagon Inline-4 TiiCo 1.8 a3 Intake Manifold, Injectors and Fuel Rail

April 26, 2012

Last week I picked up a comlpete TiiCo Vanagon inline-4 gas 1.8 VW head/3A Audi bubble block to scrounge the diesel parts from, and part out the gas-specific parts. It had the upgraded fuel injectors and the serpentine belt kit. Here’s the details on the a3/mk3 Intake Manifold Kit:

Throttle Body (not a part of the kit, but shown in background) 1HS-133-064
Intake Manifold 037-133-223AM
MAP Pressure Sensor on Manifold 06B-906-051
Fuel Rail (Fuel Distributor) 037-133-317L
Fuel Pressure Regulator (3,0 bar) 280-160-235
Fuel Injectors 037-906-031AK
Injector Seals 037-133-555C

More TiiCo info:
Vanagon TiiCo-Diesel Coolant Hoses
Vanagon TiiCo Dual Output Exhaust Manifold
Vanagon TiiCo Transmission Adapter Plate


Anchorage Renewable Energy Fair – Sat Aug 13

August 10, 2011

Yep, it’s time for Alaska’s 2011 Renewable Energy Fair!  We’re offering a FREE biodiesel and SVO seminar at noon, and will be there all afternoon with veg-converted vehicles at our booth. Hope to see you there!


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