Archive for the 'volkswagen' Category

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!

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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

Diesel VW Vanagon T3 Coolant Hoses – Part Three – Heater Hoses

March 9, 2010
Click to Enlarge

Click to Enlarge.

All Vanagons, diesel or gas, use the same heater core.

But once again, the ’82 hoses are different, as the heater shutoff valve is located under the dash, behind the glove box close to the heater core.

’83 and later Vanagons put the shutoff valve under the floor.

See Part One – Diesel VW Vanagon T3 Coolant Hoses – Engine Compartment – for details on how to read the information below:

(23) Heater Core
* ALL 251-265-303C

(9) Heater Hose (Feed) Front Heater Control Valve to Heater Core
NLA 82CS 251-265-053 (valve under dash)
* 83CS+Later 251-265-053C (valve under floor – could be cut to fit 82CS.)

(10) Heater Hose (Return) Heater Core to Adapter Fitting.
* ALL 251-265-054A (under floor)
Note:
my ’82 has both connections under the dash, and used the shorter (NLA) 251-265-053 for both feed and return, as both (9) and (10) are similar at the heater core end.

(11) Heater Hose (Feed) Cylinder Head to Front Heater Control Valve – 3900mm
NLA 82CS 251-265-055B
* 83CS+Later 251-265-055F
82 DIY:
The ’82s have 5/8” hose the entire length, except for a 1” connection to the cylinder head. Alan Felder from the Diesel-Vanagon yahoogroup suggests splicing standard 5/8” heater hose to a Gates 19663 hose (NAPA NBH11663) , which has a 1” end and a 5/8” end and is about 43” long. (Gates 18965 – NAPA NBH10965 also has a 1” to 5/8” reduction but is only 35” long). At $215 (list price 02/2010), the stock hose is pretty spendy.

(15) Heater Hose (Return) From Front – 3530mm – Connects to 3-Way Hose (6)
* ALL 251-265-057 (available but discontinued)
82 DIY:
if this isn’t just a $225 (list price 02/2010) length of 5/8” hose, I don’t know what is! Most folks recommend about 30 feet of 5/8 hose to replace the stock heater hoses.

Previous: Diesel VW Vanagon T3 Coolant Hoses – Part Two – Radiator Hoses

Next: Diesel VW Vanagon T3 Coolant Hoses – Part Four –  Expansion Tank

Not surprisingly, the 1982 Diesel Vanagons have a unique radiator, as gas Vanagons were still aircooled.  The next year, everyone go the same radiator, gas or diesel.  '82s also have a metal additonal metal feed pipe leading to the top of the radiator from the long underbody coolant pipes.  '83s also share the smaller (1.25”) diameter metal coolant pipes, while later gas Vanagons moved to larger (1.5”) diameter plastic coolant pipes.

(Radiator)
NLA 82 CS 068-121-253A  (CS >>24-C-175 000)
* 83CS+Later 068-121-253E (CS 24-D-000 001>>)

(8a) Radiator Feed Hose from Pipe. (not 82)
* 83CS+84?? 251-121-083G from small diameter (metal 1.25”) pipe.
* late CS 251-121-083H from large diameter (plastic 1.5”) pipe.

(9) Radiator (Feed) from Front Pipe & to Front Pipe from Rear (small diameter metal 1.25”) Feed Pipe. (82 only)
* 82 N900785.02  32x4x70mm (2.75" – need two - 82s have an additional front metal pipe for the radiator feed)
DIY: 1.25” heater hose.

(10-10a) Radiator Hose (Return)
* 82CS+83CS+84?? N901666.01 32x4x650mm (25.5”) to small diameter (metal 1.25”) pipe.
* late CS+KY+JX 251-121-082 to large diameter (plastic 1.5”) pipe.
DIY: 1.25” heater hose.

Diesel VW Vanagon T3 Coolant Hoses – Part Two – Radiator Hoses

March 9, 2010

Click to Enlarge.

Not surprisingly, the 1982 Diesel Vanagons have a unique radiator, as 1982 gas Vanagons were still aircooled.  Starting in 1983, a new style radiator was used for both gas and diesel models.

The ’82s and ’83s share the smaller (1.25”) diameter metal coolant pipes, while later gas Vanagons moved to larger (1.5”) diameter plastic coolant pipes.

Note that 1982 models also have an additonal metal feed pipe leading from the long underbody coolant pipes to the top of the radiator, while the later radiator style uses a rubber hose for the feed from the underbody pipes.

See Part One – Diesel VW Vanagon T3 Coolant Hoses – Engine Compartment – for details on how to read the information below:

(Radiator)
NLA 82 CS 068-121-253A (shown on right)
* 83CS+Later 068-121-253E (shown on left)

(8a) Radiator Feed Hose from Pipe. (note ’82 uses NLA (8) metal pipe)
* 83CS+84?? 251-121-083G from smaller (metal 1.25”) pipe.
* late CS 251-121-083H from larger (plastic 1.5”) pipe.

(9) Radiator (Feed) from Front Feed Pipe and from Underbody (smaller metal 1.25”) Pipe. (82 only)
* 82 N900785.02 32x4x70mm (2.75″ – need two for the ends of (8) front metal radiator feed pipe)
82 DIY: 1.25” heater hose.

(10-10a) Radiator Hose (Return)
* 82CS+83CS+84?? N901666.01 32x4x650mm (25.5”) to smaller (metal 1.25”) pipe.
* late CS+KY+JX 251-121-082 to larger (plastic 1.5”) pipe.
82-83 DIY: 1.25” heater hose.

Previous: Diesel VW Vanagon T3 Coolant Hoses – Part One – Engine Compartment

Next: Diesel VW Vanagon T3 Coolant Hoses – Part Three – Heater Hoses

2 Diesel Vanagons have a unique radiator, as gas Vanagons were still aircooled.  The next year, everyone go the same radiator, gas or diesel.  '82s also have a metal additonal metal feed pipe leading to the top of the radiator from the long underbody coolant pipes.  '83s also share the smaller (1.25”) diameter metal coolant pipes, while later gas Vanagons moved to larger (1.5”) diameter plastic coolant pipes.

(Radiator)
NLA 82 CS 068-121-253A  (CS >>24-C-175 000)
* 83CS+Later 068-121-253E (CS 24-D-000 001>>)

(8a) Radiator Feed Hose from Pipe. (not 82)
* 83CS+84?? 251-121-083G from small diameter (metal 1.25”) pipe.
* late CS 251-121-083H from large diameter (plastic 1.5”) pipe.

(9) Radiator (Feed) from Front Pipe & to Front Pipe from Rear (small diameter metal 1.25”) Feed Pipe. (82 only)
* 82 N900785.02  32x4x70mm (2.75" – need two - 82s have an additional front metal pipe for the radiator feed)
DIY: 1.25” heater hose.

(10-10a) Radiator Hose (Return)
* 82CS+83CS+84?? N901666.01 32x4x650mm (25.5”) to small diameter (metal 1.25”) pipe.
* late CS+KY+JX 251-121-082 to large diameter (plastic 1.5”) pipe.
DIY: 1.25” heater hose.

Diesel VW Vanagon T3 Coolant Hoses – Part One – Engine Compartment

February 25, 2010

Click to Enlarge.

Most diesel VW Volkswagen Vanagons (and diesel Vanagon Westfalia Campers) in the USA are from 1982, with some 1983s floating around. Both sport the 1.6 liter naturally aspirated (NA – non-turbo) engine. The ’83s have the “newer” water-cooled 5-speed style transmission. Both have a weird, mostly “no longer available” coolant hose system.

Luckily VW continued to sell Vanagon “T3” diesel models in other parts of the world. These included the same 1.6NA CS engine, as well as a 1.7NA KY engine and a 1.6TD JX Turbodiesel engine. Although these later models aren’t exactly the same, the coolant hoses should fit the USA 1982 and 1983 CS diesel Vanagons with minor modifications.

Note: The 1982 models had smaller diameter metal coolant pipes under the chassis, and smaller diameter hoses leading to the coolant pressure tank. For the 1983 models, VW moved the engine back 2 inches, kept the smaller diameter metal coolant pipes, but used larger diameter hoses on the coolant tank. Later models also had the engine further back, used the larger plastic coolant pipes common with gas models, and had the larger diameter hoses on the coolant tank (also the same as later gas models).

Basically, the 1.7 KY diesel hoses are still available (and the KY 3-way and 4-way hoses are the same as a TiiCo conversion), and should be pretty close to a stock 82 or 83 Vanagon diesel.  The 1.6TD JX hoses are close, but have an extra electric water pump.

(#) EKTA VW Electronic Parts Catalog number – see diagram.

NLA = No Longer Available 02/2010

* = Available 02/2010

82, 83 (>#CS149999), 84 (#CS150000>) = Model Year (approx.)

Engine Codes:

CS = 1.6 NA diesel

JX = 1.6 Turbodiesel (non-USA)

KY = 1.7 NA diesel (non-USA)

TiiCo = South African imported inline gas engine.

(1) Bypass Hose, Block to Water Pump
* all-CS+KY+(NOT TiiCo)+JX 068-121-053M

(3) Lower 3-Way Hose (Return) From Radiator Pipe & Oil Cooler to Water Pump
NLA 82CS 068-121-073A
* 83CS 068-121-073C
NLA 84?? 068-121-073B
* late-CS+KY+TiiCo 068-121-073G
* JX: see (JX3) note.

(6) Lower 3-Way Hose (Return) From Front Heater Core Hose to Water Pump & Expansion Tank
NLA 82CS 068-121-081
NLA 83CS 068-121-081B
* late-CS+KY+TiiC0+JX 068-121-081C

(17) Upper “Octopus Hose” 4-Way Hose Feed From Block to Radiator, Oil Cooler & Expansion Tank
NLA 82CS 068-121-101C
NLA 83CS 068-121-101E
NLA 84?? 068-121-101F
* late-CS+KY+TiiCo+JX 068-121-101H

(JX3) Note: The JX (and KY with a/c) 3-Way Hose (Return) From Radiator Pipe & Oil Cooler to Water Pump has an ADDITIONAL ELECTRIC WATER HEATER between the 3-way hose and oil cooler.
* JX+(KY with a/c) (JX3) 068-121-073H 3-Way Hose to Electric Water Pump
* JX+(KY with a/c) (JX33) 034-965-561C Electric Water Pump (also needs mount/wiring)
* JX+(KY with a/c) (JX7) 068-121-105 Oil Cooler to Electric Water Pump Hose

Note: Please support businesses that support old VW buses and vans: Van-Cafe in Santa Cruz has a TiiCo set for sale (same as KY except for the $5 bypass hose?) and The Bus Depot in Pennsylvania always has great prices, if somewhat slow shipping – I guess some parts need to come from Germany..  (P.S. thanks to Bus-Boys for the NLA list.)

Cost: You’re looking at $350-$400 (02/2010) for just the engine compartment hoses.  Nearly all of the cost is in the three funky hoses.  Used JX hoses from Germany are available from vanagon.eu (ebay/thesamba seller), while Justin over at Greaseworks sells a “lifetime” silicone set of the engine compartment hoses.

Next: Diesel VW Vanagon T3 Coolant Hoses – Part Two – Heater Hoses

I’m not quite sure what changed between 83 and 84, why some hoses are different from the later KY? Please comment for any corrections or other hose number options!