Dan j

Building a mk6 escort van with a late w reg escort tdi engine complete with aircon.. heres there doner.. mot till sept



The plan is to swap the entire front end and interior loom so gaining elec windows and mirrors central locking and air con.. with it being a late spec escort they tend to have high spec fuse boxes so I could probs have electric seats and heated screen.

The van is a ex royal mail on a 51 so its red/pink which is perfect for what I want. No pics of that yet untill it arrives on Saturday. More to come

Dan j

Finally got to make a start on the van over the weekend, previous owner did block paving so van was full of soil an crap. Soon got into stripping it, there was a bad power steering leak so engine bay was minging. Few bits of welding needed and body is covered in dents but it will do for what its intended. Some pictures..







Still loads to do thought id have a look at how the fmic would sit with the air con rad etc


With a packed engine bay its going to be fun routing the pipe work but I dont mind a challenge. Doner car is 90% stripped now just need to remove interior loom then the swap over can commence. Thanks for looking.

Dan j

Got the engine and stuff fitted today along with suspension.. rs2000 brakes and braided hoses. Next is fitting the loom an making sure the air con works. Few pics




Intercooler fits nice with the rads just got to work out a route of the pipe work as the engine is mighty tight for space..



Thanks for looking.

Dan j

Intercooler mounted and bumper test fitted

Fits nice an i can refit the original grill too, my mate has also started on the boost pipes 1 of the will run through the inner wing due to space in the engine bay.


just waiting on a focus tddi inlet and hoses..

Ben26

looks like an interesting project there mate

what engine mods u doing then ?, or u just sticking the cooler on and that's it

Ive got the same escort estate as your doner car with the intercooled diesel lump in, goes alright for what it is.

Dan j

Adjusted the fueling on the pump and on boost fueling and shortened the actuator arm on the turbo and removed the egr crap.

Hoping for 130bhp odd

Ben26

seen a few guides how to adjust the fueling, seems a bit er.......cowboy lol

Dan j

Would say its a tried and tested method and its free

turbo m

iTrader: (2)

love the number plate on the van.A nice project think iam right in saying you can run a max of 20psi boost on these td"s?? will be watching this..

Dan j

Not sure to be honest im sure ill find out anything over 130bhp id be happy,, its pretty much staying unloved on the outside.

Dan j

Got all the boost pipes made and welded up.. got to love exhaust pipe. Heres some pics
Yeah it isn't going to fordfair anyway Update. .

Dan j

You'd never know..steel wheels next




Note the aftermarket washer bottle.. no space for the original.

Focus tddi inlet manifold and blanked egr

Center grill in and fogs stealthy intercooler set up


A erm testing video
http://static.photobucket.com/player...ps4a053a34.mp4

Oh an a tdi with chatter
http://static.photobucket.com/player...psa2788bdc.mp4

Exhaust to make.. axle to flip plus other odds and sods to sort. . Ill update next week peace out

Dan j

Quick update.

Exhaust made, axle flipped, extra leaf springs added, brakes bled with dot 4 and cossies on



Probs about 2 days worth of little jobs to do then its mot time.

Dan j

Some more pics



Mot is for monday so I have a full weekend on it.. thanks for popping in

Glenn_

iTrader: (1)

That lookd mint.Please say your leaving the escos wheels on.

RichieST

iTrader: (2)

Cool project, chatters well!!!

Dan j

If only it was mint in person Glenn cossies are staying put, Richie to make It chatter you have to rev it right up then switch the engine off. Then with the valves closed it then chatters I wont be doing that a lot, was funny at the time.

Glenn_

iTrader: (1)

Glad the wheels are staying.

SBT83

Me too

Minirotty

Nice

Dan j

So since wednesday I've done about 300 miles 200 of those was practically running non turbo... so thinking turbo was at fault it got swapped on sunday. Did it sort it no... so checked all hose connections and the hard pipes no issues there.. so thinking what the hell is it. Turns out it was an issue with the focus inlet, where the erg usually is theres a steel circle insert with the egr plunger set up. I had welded it up so it was blocked off so what happened was the 12psi the turbo ran at the beginning blew the insert out. Now you'd think surely you would of heard the air leak but there was non anyway plate made up bolted on. Hello power !!! Upto now its ran perfect if a little too much fueling but pretty happy. Next weekend ill sort the on boost fuel and actuator and aim for 18psi. Few pics of the dirty shed. .




Fitted the bumper under trays and filled the gaps either side of the intercooler so air has to pass through it and not either side. . Couple of pics




Not the clearest of pics but look a bit closer and you should spot them lol..

Thanks for looking.

Dan j

Engine bay shot... just got to get the rocker cover painted. .

packman

Will boost hoses that long it will take a age to boost up .... boost hoses are to be kept as short as possible.

Dan j

Only time I see its an issue is pulling off from standstill. . The tdi originally didnt have any boost pipes with the standard top mount.