VW Bus Engine Swap to AUDI 5E

Swap to Water Cooling System

	The expansion tank have to be in two parts: One real expansion tank on the left, and one water reservior at the right. The pressurazied expansion tank is within the cooling circuit between the hot forward to radiator (upper flange) and cold return from passenger heater (lower flange). The flow of cooling through the expansion tank from the hot forward hose has to be limited by a hose or mounting flange with an inner diameter of 3mm. I took the Diesel hose as a connector between engine and plastic cooling pipes to the front. There is a third hose to be connected to the oil cooler, but I redirected it to the expansion tank and connected it with a aluminium flange, wich fits the rubber hoses and does have the 3mm flow limiter. The water reservior is connected with a short hose to the upper hole of the expasion tank near its cap. In this way the expansion tank will breath water instead of air and it works as an air bubble trap.
	At the rear end I had to weld a support bar for the cooling pipes and the exhaust system. The support is secured at the fire wall at the top end, and at one of the mounting holes for the Diesel engine support at the Vanagon frame rails. The U-shaped brackets do have a full thread end to end. I slipped a pice of rubber fuel hose over it and tighted the brackets slightly.
	The front end of the plastic radiator pipes. They came from the '87 Crew Cab. The pipes have to fit the radiator of the '80 Diesel as this old design used steel pipes. The diameter of the steel and plastic pipes are different, but the rubber hoses of the later cooling system fits both plastic tubes and radiator flanges. After one years of driving I have no leaks. The old steel pipes tends to rust, specially at the knee below the radiator at the forward line. I cutted the pipe just obove that knee and had to keep the upright part. The newer radiators would have a nice platic frame with integrated pipe, but I had to attach the old radiator to the new rubber hose. Left and right beside the plastic pipes are the rubber hoses for the passenger heater. On the right side is the paper duct for the rear hot air distrubutor. The duct ends on top of the fuel tank where I closed it with a dead end of some house installation pipes.
	The bottom view of the front end of the Camper. You should should click on the picture to find the enlarged one. The hoses are not connected to the plastic pipes. There is only less space to run the paper duct, but it fits and there is still enough air flow for cooling in the not so hot German summer. Up to now the radiator hadn't switch to high speed, and during driving it is usually switched off. I tried some noise and heat isulation to to passenger compartment with some aluminium coated bitumen. The bitumen is still in place, but the aluminium fell off. Anyway, it isn't too hot and I keep it as it is.
	This are the temp sensors and wiring of the old '80 Diesel. They are two with different switch temperatures for low and high fan speed. The upper one, used for low speed, is connected with two wires of same color: red/black. It connects the 12V power directly to the fan. The lower sensor for high speed is connected to two thin wires wich drives a relay. This relay is mounted just below the A-pillar inside the dash board and is not to be found on the ralay frame. Both wires are of same color: red/blue.
	The bottem view, where the heater pipes enters the passergers compartment. The rubber support was found in the '80 Diesel at the floor. I mounted them top of the middle console and the heat regulator is outside the inner compartment. This prevents some noise if the regulator is opened for very less heating. The big paper duct right hand is a relict from the aircooled days, I will use it in future to bring hot air to the rear warm air distributor. Rear passengers likes to have warm feet, too, I guess.
	The top view, you see the vacuum pipe and brake line in the left, the (still) open end of the hot air duct and the two rubber pipes for the passenger heater on the right side. It will be some work to make the adapter between the paper duct and the front air distributor.

Last updated 20. Jun. 98 by Helmut Zeidler

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