engineers

121
I cannot see any reason for you to go Subaru. People go Subaru because they are changing from one boxer to another. If you have an in line four, then replace it with an in line four.

A 1,9 TDI would be the best, but you could use one of many Audi/VW/Seat/Skoda petrol engines as a straight swap.



> Gary Cookson <gary@twentytwentyone.net> wrote:
>
> Hi all
>
> I'm after some thoughts on repowering my diesel Syncro.
>
> It's been at a workshop in Thomastown for the last two weeks. When they
> put it on the dyno it was pumping out an earth shattering 28kw at the
> wheels.
>
> It seems the fuel pump is totally worn out and needs rebuilding (as per
> Greg E's excellent online diagnosis ;). Estimated cost of this is
> minimum $1200, max $1800 plus cost of exploratory work so far and the
> remove refit is likely to be in the region of $2 to 3k to get it out of
> there.
>
> I'm getting them to pressure test the engine to try and determine if the
> compression is up to spec to decide if this is worth doing. I've
> considered tracking down a secondhand pump and getting them to fit that
> but that is in itself is a potential can of worms if the pump is also
> tired. Apparently pumps removed from vehicles have a short shelf life
> because the seals shrink and harden when not soaking in diesel.
>
> The engine was rebuilt with a new head approx 40k ago but the engineer
> working on it thinks the poor fuel flow and timing may have been pumping
> too much fuel in and washing the bores of oil. There is oil in the
> smoke. The pressure test should reveal any damage this may have caused.
>
> So, do i cut my losses now and put the pump rebuild money into a repower
> with another VW diesel, VW petrol (inline 4) or a Subaru motor?
>
> If so is there anyone in Melbourne who could do the work?
>
> There is plenty of info available on UK websites on suitable engines and
> kits where needed for diesels but the supply of suitable donors for
> diesels in Oz is not great.
>
> Subaru is an option but not sure on the final drive ratio on my diesel
> which is lower than the wasserboxer equipped vehicles.
>
> Thoughts please?
>
> Cheers
> Gary
122

Hi Gary,

Negative, mine is a half Golf imported from Japland it is original VAG and possibly one of the last they built with mechanical pump arrangement. No computer with this one.

Hartmut

 

 

From: Syncro_T3_Australia@yahoogroups.com [mailto:Syncro_T3_Australia@yahoogroups.com] On Behalf Of Gary Cookson
Sent: Friday, 23 July 2010 4:27 PM
To: Syncro_T3_Australia@yahoogroups.com
Subject: Re: [Syncro_T3_Australia] Repowering

 

 

Hi Hart, I thought yours was a TDi with a fancy converted to manual pump from Bernd Jaeger?

 

 

[2 0 / 2 1 Design]
28 Gwynne St
Richmond
Vic 3121
gary@twentytwentyone.net
www.twentytwentyone.net
Tel 3 9429 1868
Fax 3 9421 1110
Mob 0417 352782

 

On 23/07/2010, at 3:15 PM, Hartmut Kiehn wrote:



 

 

Although about every soul in the group knows that there is an AAZ  127 000

 

From: Syncro_T3_Australia@yahoogroups.com [mailto:Syncro_T3_Australia@yahoogroups.com] On Behalf Of Gary Cookson
Sent: Friday, 23 July 2010 2:34 PM
To: Syncro_T3_Australia@yahoogroups.com
Subject: Re: [Syncro_T3_Australia] Repowering

 

 

Greg, i think this is my most viable solution. An AAZ seems to be a pretty similar engine to the 1.6td. I'm about to move my business into new premises and there is a storage area just big enough to get a dirty stinking old syncro into for a bit of a stripdown...

 

I'll wait to get the verdict on the state of compression and then consider the pump rebuild first. 

 

[2 0 / 2 1 Design]
28 Gwynne St
Richmond
Vic 3121
gary@twentytwentyone.net
www.twentytwentyone.net
Tel 3 9429 1868
Fax 3 9421 1110
Mob 0417 352782

 

On 23/07/2010, at 1:42 PM, greg esposito wrote:




 

Gary, Lots of things to consider, I think a big thing to consider is if you are paying someone to do the job the less modification involved, the better (for you bank balance). The subi will involve a bellhousing, mounting, hose and wiring adaption. Converting to petrol - easiest solution would be to wreck a cheap 2wd (as scott said your tank will be fine with a flush). Then I think the easiest solution is a 1.9tdi with a mechanical pump. As I understand it same bell housing, mounting, plumbing and wiring more or less. You may have to pay through the nose for the pump but compared to labour involved in the other options it is viable. Have you tried to get price and avilability of an AZZ? Greg E

--- On Fri, 23/7/10, Francesca Coles <fcoles6@gmail.com> wrote:


From: Francesca Coles <fcoles6@gmail.com>
Subject: Re: [Syncro_T3_Australia] Repowering
To: Syncro_T3_Australia@yahoogroups.com
Received: Friday, 23 July, 2010, 1:11 PM

 

Gary, surely the rest of the family wouldn't mind if you cannabalised your Forester, and ended up with a Subaru-powered camp mobile? But then again, maybe they might... 

 

Glad to see you're getting some really good advice, anyway, and I hope more rolls in. It's quite a project and there's a lot to weigh up.

 

Good luck,

 

Francesca.

On Fri, Jul 23, 2010 at 12:40 PM, Scott Daniel - Turbovans <ScottDaniel@ turbovans. com> wrote:

 

that sure is a low ring and pinion ratio.

with larger tires and an engine that doesn't mind a few rpm .....and you're not trying to go say 140 Kph very often ...should work out well enough I'd think.

 

Diesel was probably less than your regular petro there, once upon a time.

In this last big gas crisis we had about 3 years ago ..

diesel got even more expensive than premium petrol ..

and it's still about the same price as mid-grade petrol,

and it's not likely that it will get below the price of petrol from what I can gather, at least not for the foreseeble future.

  from what I have read the refinning process dictates how much petro or diesel can be made from a barrel of oil. I read that in europe, where they burn a lot of diesel...with the refinning process they use, they end up with ...I think this is right..

with more petrol than they really need, and they export petrol. 

 

I recognize only 5 advantages of diesel that I can see so far ..

 

ability to run biofuels - can even run on cooking oil from the grocery store in an emergency

further range on a given load of fuel

better fuel milage

less fire hazzard

and the other one escapes me right now ..maybe better low end torque .

 

and it used to be 'simplicty thus reliability' ..

but I don't think that's the case any more too much ..

modern eletronics are so reliable in petrol engines .

and the unforgving nature of diesel engines....well, in a Mercedes ....those are super well made and will run indefenitey until finally the timing chain wears out ..

but in VW diesels....really, I am reading about blown tdi turbo's and broken timing belts all to commonly.

 

then when you factor in rougher running, smoking sometimes, smelly sometimes ...and lower power in many versions .....

been there done that !

lol.

Scott

turbovans

 

----- Original Message -----

From: Les Harris

Sent: Thursday, July 22, 2010 7:15 PM

Subject: RE: [Syncro_T3_Australi a] Repowering

 

 

Scott,

Thanks for the excellent input.

I will add a couple of items.  All Australian delivered Syncros came with 5.43, a factor to be considered when looking at engine changes.

Diesel in Australia is a lot more expensive than petrol and this is never going to change, so amortisation will take an unrealistically long time.

Les

_,_._,___


 

 

 

 

123
On Thu, Jul 22, 2010 at 8:25 PM, Les Harris <leslieharris@optusnet.com.au> wrote:


Scott,

I thought so when I first bought my Syncro but have since found that this gearing makes for very easy travelling on gravel roads.

The combination of gear spread, final drive ratio, weight distribution and very precise handling results in being very comfortable at speeds that most vehicles on the same roads just can’t maintain.

Les

Les, et al.,
It has been my experience from being on various forums in several continents that most of do not have a true appreciation for the other's specific circumstances. Best to take advise from the locals when it comes to such details.
--
BenT
124
Hello Gary
                  As Roger said I had the 2.1 replaced with a 1.9TDI. I had had a diesel obsession for many years   and came by an engine so in it went. Good decision? probably not, gearing being the main one. Still it's not bad now with the bigger tyres. Drive about 95kph. Get about 10 litres/100 at that speed, less of course if I go faster. Just enough power. As you have the better gearing yours would be a lot better. I still like the way the diesel drives at slower speeds.

Have you looked at this list  TDI-conversion@yahoogroups.com,

At the moment I would throw it away as it has a problem. The vacuum tubes that tell the ecu how much boost to give just keep coming off. I taped them on and then one blew off from the N75 valve. So I have a problem. Searching the TDI conversion list it could be anything from clogged tubes, N75 or a stuffed turbo. Any suggestions welcome.

Bruce


125
Hi Bruce, hmm sounds interesting despite the problems, did you do the conversion yourself?

How did you get round the electronic pump issue?

Gary

[2 0 / 2 1 Design]
28 Gwynne St
Richmond
Vic 3121
gary@twentytwentyone.net
www.twentytwentyone.net
Tel 3 9429 1868
Fax 3 9421 1110
Mob 0417 352782

On 25/07/2010, at 12:59 PM, Alison & Bruce Black wrote:

 

Hello Gary

                  As Roger said I had the 2.1 replaced with a 1.9TDI. I had had a diesel obsession for many years   and came by an engine so in it went. Good decision? probably not, gearing being the main one. Still it's not bad now with the bigger tyres. Drive about 95kph. Get about 10 litres/100 at that speed, less of course if I go faster. Just enough power. As you have the better gearing yours would be a lot better. I still like the way the diesel drives at slower speeds.

Have you looked at this list  TDI-conversion@ yahoogroups. com,

At the moment I would throw it away as it has a problem. The vacuum tubes that tell the ecu how much boost to give just keep coming off. I taped them on and then one blew off from the N75 valve. So I have a problem. Searching the TDI conversion list it could be anything from clogged tubes, N75 or a stuffed turbo. Any suggestions welcome.

Bruce




126
I was told the other day that Tooleys has one of the pipes in stock. But it could be for 2WD.
Syncro part numbers are 251 121 397 L for the feed.
251 121 399 L for the return.

Phill



> Alison & Bruce Black <royalb@aapt.net.au> wrote:
>
> Hello Roger
> Thanks for the info. Haven't done anything about
> them yet.
>
> As Phil says original pipes are available from classic parts de for
> ���116 each.
>
> Stainless steel from quite a few places for around the US$350 mark.
>
> Ken the local dealer told me he could get that hose in 10 foot
> lengths. Haven't asked the cost yet.
>
> My mechanic told me with hose you have to support it very well or you
> could get air locks in it. Hence I guess the reason VW used pipes in
> the first place, although there seem to be quite a few people in the
> US using hose successfully. If I went that way one of my hoses could
> be just one piece from radiator to engine. Not sure about the other.
>
> Bruce
>
> ------------------------------------
>
> Yahoo! Groups Links
>
>
>
127
Gary
        No didn't do the conversion myself, am a little mechanically challenged. Well actually pretty hopeless with engines. It's not the best of jobs but has been going ok for 5 years, about 90,000 k's. One problem is that little stones fly up and puncture the ribbed belt. I have a bash plate but the whole bottom needs to be protected somehow, like in the factory diesel. 

Blew out the vacuum lines with my compressor and mucked around a bit and went for a 53km drive and it went fine. So am off to Brisbane tomorrow so hopefully all will be well, fingers crossed. 

Bruce 


On 25/07/2010, at 1:40 PM, Gary Cookson wrote:

 

Hi Bruce, hmm sounds interesting despite the problems, did you do the conversion yourself?


How did you get round the electronic pump issue?

Gary

[2 0 / 2 1 Design]
28 Gwynne St
Richmond
Vic 3121
gary@twentytwentyon e.net
www.twentytwentyone .net
Tel 3 9429 1868
Fax 3 9421 1110
Mob 0417 352782


128
Thanks Bruce, hope it all runs smoothly for you. Where are you? If in Melbourne i would love to have a look at it if you wouldn't mind?

The bash plates would be relatively easy to make, just pieces of fairly thin sheet steel, you are welcome to use mine as a pattern if needed.

Gary
[2 0 / 2 1 Design]
28 Gwynne St
Richmond
Vic 3121
gary@twentytwentyone.net
www.twentytwentyone.net
Tel 3 9429 1868
Fax 3 9421 1110
Mob 0417 352782

On 25/07/2010, at 7:55 PM, Alison & Bruce Black wrote:

 

Gary

        No didn't do the conversion myself, am a little mechanically challenged. Well actually pretty hopeless with engines. It's not the best of jobs but has been going ok for 5 years, about 90,000 k's. One problem is that little stones fly up and puncture the ribbed belt. I have a bash plate but the whole bottom needs to be protected somehow, like in the factory diesel. 

Blew out the vacuum lines with my compressor and mucked around a bit and went for a 53km drive and it went fine. So am off to Brisbane tomorrow so hopefully all will be well, fingers crossed. 

Bruce 


On 25/07/2010, at 1:40 PM, Gary Cookson wrote:

 

Hi Bruce, hmm sounds interesting despite the problems, did you do the conversion yourself?


How did you get round the electronic pump issue?

Gary

[2 0 / 2 1 Design]
28 Gwynne St
Richmond
Vic 3121
gary@twentytwentyon e.net
www.twentytwentyone .net
Tel 3 9429 1868
Fax 3 9421 1110
Mob 0417 352782




129
Gary
         I live near Rockhampton so quite a way from Melbourne. 

Yes, I need to get on with the underbody protection!!!!

Bruce
On 25/07/2010, at 8:32 PM, Gary Cookson wrote:

 

Thanks Bruce, hope it all runs smoothly for you. Where are you? If in Melbourne i would love to have a look at it if you wouldn't mind?


The bash plates would be relatively easy to make, just pieces of fairly thin sheet steel, you are welcome to use mine as a pattern if needed.

Gary
[2 0 / 2 1 Design]
28 Gwynne St
Richmond
Vic 3121
gary@twentytwentyon e.net
www.twentytwentyone .net
Tel 3 9429 1868
Fax 3 9421 1110
Mob 0417 352782

On 25/07/2010, at 7:55 PM, Alison & Bruce Black wrote:

 

Gary

        No didn't do the conversion myself, am a little mechanically challenged. Well actually pretty hopeless with engines. It's not the best of jobs but has been going ok for 5 years, about 90,000 k's. One problem is that little stones fly up and puncture the ribbed belt. I have a bash plate but the whole bottom needs to be protected somehow, like in the factory diesel. 

Blew out the vacuum lines with my compressor and mucked around a bit and went for a 53km drive and it went fine. So am off to Brisbane tomorrow so hopefully all will be well, fingers crossed. 

Bruce 


On 25/07/2010, at 1:40 PM, Gary Cookson wrote:

 

Hi Bruce, hmm sounds interesting despite the problems, did you do the conversion yourself?


How did you get round the electronic pump issue?

Gary

[2 0 / 2 1 Design]
28 Gwynne St
Richmond
Vic 3121
gary@twentytwentyon e.net
www.twentytwentyone .net
Tel 3 9429 1868
Fax 3 9421 1110
Mob 0417 352782





130
Bruce,

If you're getting some from classic parts let me know.
I'd like spares.

Phill


> plander@optusnet.com.au wrote:
>
> I was told the other day that Tooleys has one of the pipes in stock. But
> it could be for 2WD.
> Syncro part numbers are 251 121 397 L for the feed.
> 251 121 399 L for the return.
>
> Phill
>
>
>
> > Alison & Bruce Black <royalb@aapt.net.au> wrote:
> >
> > Hello Roger
> > Thanks for the info. Haven't done anything about
> > them yet.
> >
> > As Phil says original pipes are available from classic parts de for
> > �������116 each.
> >
> > Stainless steel from quite a few places for around the US$350 mark.
> >
> > Ken the local dealer told me he could get that hose in 10 foot
> > lengths. Haven't asked the cost yet.
> >
> > My mechanic told me with hose you have to support it very well or you
>
> > could get air locks in it. Hence I guess the reason VW used pipes in
> > the first place, although there seem to be quite a few people in the
> > US using hose successfully. If I went that way one of my hoses could
> > be just one piece from radiator to engine. Not sure about the other.
> >
> > Bruce
> >
> > ------------------------------------
> >
> > Yahoo! Groups Links
> >
> >
> >
>
>
> ------------------------------------
>
> Yahoo! Groups Links
>
>
>
131
ahah yes that does make it a bit tricky!


On 25/07/2010, at 9:06 PM, Alison & Bruce Black wrote:

 

Gary

         I live near Rockhampton so quite a way from Melbourne. 

Yes, I need to get on with the underbody protection!! !!

Bruce
On 25/07/2010, at 8:32 PM, Gary Cookson wrote:

 

Thanks Bruce, hope it all runs smoothly for you. Where are you? If in Melbourne i would love to have a look at it if you wouldn't mind?


The bash plates would be relatively easy to make, just pieces of fairly thin sheet steel, you are welcome to use mine as a pattern if needed.

Gary
[2 0 / 2 1 Design]
28 Gwynne St
Richmond
Vic 3121
gary@twentytwentyon e.net
www.twentytwentyone .net
Tel 3 9429 1868
Fax 3 9421 1110
Mob 0417 352782

On 25/07/2010, at 7:55 PM, Alison & Bruce Black wrote:

 

Gary

        No didn't do the conversion myself, am a little mechanically challenged. Well actually pretty hopeless with engines. It's not the best of jobs but has been going ok for 5 years, about 90,000 k's. One problem is that little stones fly up and puncture the ribbed belt. I have a bash plate but the whole bottom needs to be protected somehow, like in the factory diesel. 

Blew out the vacuum lines with my compressor and mucked around a bit and went for a 53km drive and it went fine. So am off to Brisbane tomorrow so hopefully all will be well, fingers crossed. 

Bruce 


On 25/07/2010, at 1:40 PM, Gary Cookson wrote:

 

Hi Bruce, hmm sounds interesting despite the problems, did you do the conversion yourself?


How did you get round the electronic pump issue?

Gary

[2 0 / 2 1 Design]
28 Gwynne St
Richmond
Vic 3121
gary@twentytwentyon e.net
www.twentytwentyone .net
Tel 3 9429 1868
Fax 3 9421 1110
Mob 0417 352782