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  #1  
Old 05-20-2020, 09:58 AM
Nevadan Nevadan is offline
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Default 2.0TD into 1987 VW Quantum Syncro Wagon

It's been years since I've been on here!

I'm going to start my diesel conversion project this weekend, putting a 1983 2.0TD (I think it was from an Canadian Audi 5000) into my 1987 QSW. I'll log my progress here and will take some pictures this weekend after beginning the work.

I've had the 2.0TD running on a stand (six years ago) but am going to take it apart and inspect everything, installing new rings, bearings and seals as needed. I miraculously found a spare rebuilt head six years ago if there's major problems with the current head and have already gathered gaskets and seals.

A few things I'm still considering and/or still need are:

Finding an alternator bracket that will fit the passenger side so I can move the gasser alternator from the driver's side making more room for an oil cooler, larger radiator and possibly an inter-cooler. I know I can fabricate one but would prefer an original part.

Plumbing a coolant outlet on the back of the head that will constantly flow coolant back to the thermostat thus keeping hot water flowing through the head when the heater is off. V8VOLVO had some good input on this several years ago when I was considering this project.

Finding a spot for the battery, possibly in the space created by moving the alternator or moving it to the rear of the car, opposite the spare tire.

Replacing the rust rotted oil pan with the one from the 2.2 gas engine, if it will fit, or just brazing the pitted pan until a 2.0 pan can be found.

This is going to be a months-long project and I'm beyond anxious to finally be starting it. The car is located 100 miles from my home in a nice concrete floored shop and I plan on working on it every weekend.
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J.D. in Reno
1958 Mercedes 180D (rebuilding now)
1985 VW Jetta 1.6TD
1985 Volvo 745 Wagon 2.4TD (sold but still maintain it)
1987 VW Quantum Syncro 2.2 (converting to 2.0TD)
1996 TDI Passat
1997 Chevy 3/4 ton 6.5TD
2006 V10 TDI Touareg
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  #2  
Old 05-20-2020, 12:16 PM
Goteborg Vapenfabrik Goteborg Vapenfabrik is offline
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Nice find. Is the oil pan from the 2.0TD steel?
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  #3  
Old 05-20-2020, 05:04 PM
Nevadan Nevadan is offline
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Quote:
Originally Posted by Goteborg Vapenfabrik View Post
Nice find. Is the oil pan from the 2.0TD steel?
It is a steel pan. I will know if it will fit once I get the 2.2 gas engine out of the QSW.
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J.D. in Reno
1958 Mercedes 180D (rebuilding now)
1985 VW Jetta 1.6TD
1985 Volvo 745 Wagon 2.4TD (sold but still maintain it)
1987 VW Quantum Syncro 2.2 (converting to 2.0TD)
1996 TDI Passat
1997 Chevy 3/4 ton 6.5TD
2006 V10 TDI Touareg
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  #4  
Old 05-20-2020, 08:16 PM
v8volvo v8volvo is offline
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Nice to see you here again!

Sounds like a fun project and engine-car combination. I always heard those Quantum Syncros were really an Audi Coupe Quattro underneath, but in VW station wagon clothing. Supposed to be great to drive. I knew a guy who had one and sold it and missed it afterwards. I imagine the 2.0 TD will be capable of similar performance to the stock nonturbo gasser, and much better mileage, no?

What's the motivation for the swap, just the benefit of turbodiesel power, or does the current gas engine have problems?

I think you will find the 2.0 TD very familiar to the D24T. Even all the same special tools for the crankshaft dampener and bolt, etc. Be fun to see your pictures for comparison to our engines. A lot of the parts are probably the same too, like the IP mounting bracket, cooling system parts, etc, right?

I bet that 2.2 gasser oil pan will bolt right onto the 2.0 TD (though maybe the TD needs a turbo drain return to the pan so that might be a problem to solve?). All accessory component mountings on the front of the engine should be the same too IIRC, with all the same bolt holes and bosses available, AND should also be the same as a 6-cylinder D24 or D24T. So that might be one easy solution to your idea of relocating the alternator to the passenger side, as it's already positioned there on a D24. A D24 or D24T alternator bracket and alternator would likely bolt right on. You might need to trim the bracket a little to remove the bearing housing for the engine driven rad fan (I assume the Audi/QSW don't use those?). Belt alignment might be a question if the Audi engines use a differently designed crankshaft harmonic balancer, I guess.

Look forward to seeing your updates. In case it gives any useful ideas, have you already seen this thread on a similar swap into an Audi 5000? http://vwdiesel.net/forum/index.php/topic,25252.0.html
Slightly different car and he used the long stroke 2.4L nonturbo truck version of the 5cyl IDI for the engine in his and added a turbo to that, but same general idea, gas 5cyl to 5cyl TD. I ran across it accidentally looking for info on something else, but bookmarked it anyway, mainly just since the guy seemed to do an especially nice job with the conversion and put up some great photos. Fun reading and watching at least.
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86 745 D24T/ZF 340k lifted 2.5"
83 764 D24T/M46 145k
93 Toyota 4x4 pickup 1.9 TDI swapped
04 Audi Allroad 2.0 TDI swap in progress
02 F250 SD 5.4/4R100
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  #5  
Old 05-20-2020, 09:21 PM
Nevadan Nevadan is offline
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The QSW really does handle well and the 4WD system is excellent, locking rear and center differentials using a two position vacuum switch. The 2.2 gas engine is tired and using oil and just doesn't run right. And I want an AWD diesel station wagon that gets 30mpg. I have another 1985 QSW 2.2 gas vehicle and it gets a little over 20mpg and runs well. It's basically an unregistered backup vehicle and will be used for drivetrain parts if necessary in the future.

The 2.0TD looks exactly the same as the 2.4, minus the one cylinder, which is why I'm on this site, the veterans here know what they're looking at, and yes, all the tools are the same and I have enough experience with the 1.6's and 2.4 to also know what I'm looking at.

The turbo drain is plumbed into the block so if the bolt holes line up I'll be fine.

The harmonic balancer is the same as the 2.4 and the gas engine uses an electric fan on the radiator mounted beside the engine, you'll be able to see it in the photo's soon.

I will need to get either and Audi alternator bracket or the Volvo bracket to bolt on the passenger side and will post a "parts wanted" add in a few days.

I did find that other thread and read the entire thing a few days ago. The one major concern I had is the gear ratios being to low for a diesel but I'm doing it anyway. It drives 70mph at around 3200 rpms so it will be fine for it's intended use, a ski-mobile, mostly winter driving on mountain roads around Reno.

I'll get some photo's tomorrow and post them with a few questions.
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J.D. in Reno
1958 Mercedes 180D (rebuilding now)
1985 VW Jetta 1.6TD
1985 Volvo 745 Wagon 2.4TD (sold but still maintain it)
1987 VW Quantum Syncro 2.2 (converting to 2.0TD)
1996 TDI Passat
1997 Chevy 3/4 ton 6.5TD
2006 V10 TDI Touareg
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  #6  
Old 05-21-2020, 05:53 AM
anders anders is offline
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Sounds like a cool project!
I met a guy that was trying to do a similar project in yoncalla Oregon, he was hoping to use a d24t, but space didnt allow so he acquired the 2.0TD to use. He has a HUGE collection of 80s VWs and 1.6 diesels.
Anyways, I always have lots of d24/d24t parts of you need anything for the project.
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12mm pump heads, ARP stud kits and GTD nozzles available! http://d24t.com/showthread.php?t=1646
NA intake manifolds and 240 turbo pans for sale.
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1982 242 D24+T/M46- Super pumped! Build thread:
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1984 764 D24T/ZF build thread: http://www.d24t.com/showthread.php?t=1734
Diesel parts cars: 82 244,83 244, 84 244, 84 245, 85 745
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  #7  
Old 05-21-2020, 08:34 AM
Goteborg Vapenfabrik Goteborg Vapenfabrik is offline
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Ive discovered saving sheet steel parts that are badly rusted to be a simple process with the oxy-acetylene powered DHC 2000 welding kit. It could be a valuable tool for your 2.0TD oil pan repair project. It can be used with standard regulators. Of course as always safety first.
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  #8  
Old 05-21-2020, 08:11 PM
v8volvo v8volvo is offline
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Quote:
Originally Posted by Nevadan View Post
The one major concern I had is the gear ratios being to low for a diesel but I'm doing it anyway. It drives 70mph at around 3200 rpms so it will be fine for it's intended use, a ski-mobile, mostly winter driving on mountain roads around Reno.
I was going to ask what you were planning to do about gearing, but then I didn't because I think you're right, the gasser gearing will probably be fine as is. These old IDI motors like to rev and there are seemingly no downsides to letting them do it. In the example of the Volvos, the diesel models use exactly the same transmission and rear axle gearing from the factory as most of the equivalent gas models. In fact the diesels are actually geared shorter than some of the NA gassers. The engines are suited by design for fairly high engine speeds, small lightweight pistons, direct acting OHC valvetrain, etc, it was clearly part of the plan for them. Especially true for the original design "short stroke" family like the D24/T and your "D20T" (the 1.5/1.6 4cyl, 2.0 5cyl, 2.4 6cyl). The raised deck generation IDI and TDI motors (1.9/2.0 4cyl and 2.4/2.5 5cyl) with longer strokes are maybe a little less optimized for it.

Anyway if the gas engine is turning 3200 at 70 that seems like it would be just fine with the diesel. My '83 760 D24T with stock size tires and stock gearing turns about 3400 rpm in overdrive at 85mph, which is still too slow to keep up with highway traffic here. But it seems happy to do those revs or more all day, in fact it seems to be capable of quite a bit more, although with the 1983-only 85mph speedo I am not too tempted to explore. Really the ability to rev smoothly and provide a wide power band is one of the neat features of the old IDI turbo engines, and makes them fun to use for hard driving. The later direct injection engines are much more limited on the top end, although their low end response is better. They seem to pretty much run out of breath even before 4000 rpm.
__________________
86 745 D24T/ZF 340k lifted 2.5"
83 764 D24T/M46 145k
93 Toyota 4x4 pickup 1.9 TDI swapped
04 Audi Allroad 2.0 TDI swap in progress
02 F250 SD 5.4/4R100
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  #9  
Old 05-21-2020, 09:55 PM
Nevadan Nevadan is offline
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I'll answer all your replies tomorrow but here's an update from today.

Some before pictures, first the QSW it's going into, engine bay with the 2.2 gas engine, all stock.


__________________
J.D. in Reno
1958 Mercedes 180D (rebuilding now)
1985 VW Jetta 1.6TD
1985 Volvo 745 Wagon 2.4TD (sold but still maintain it)
1987 VW Quantum Syncro 2.2 (converting to 2.0TD)
1996 TDI Passat
1997 Chevy 3/4 ton 6.5TD
2006 V10 TDI Touareg
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  #10  
Old 05-21-2020, 09:58 PM
Nevadan Nevadan is offline
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Join Date: Jan 2013
Location: Reno, Nevada
Vehicle: 740/745 D24T will be mine again soon
Posts: 227
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And now the pre-teardown 2.0TD, very, very similar to the D24T



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J.D. in Reno
1958 Mercedes 180D (rebuilding now)
1985 VW Jetta 1.6TD
1985 Volvo 745 Wagon 2.4TD (sold but still maintain it)
1987 VW Quantum Syncro 2.2 (converting to 2.0TD)
1996 TDI Passat
1997 Chevy 3/4 ton 6.5TD
2006 V10 TDI Touareg
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