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 T3 1.6D to 1.9TD convertion

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The G
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PostSubject: T3 1.6D to 1.9TD convertion   Tue Jul 21, 2009 12:58 pm

As some of you may know my 1.6D engine gave up due to age.
The waterways in the head had corroded causing it to over pressurize the water.

I have managed to get hold of a 1.9TD engine.
It needs some mods to make it work but as it is physically it will slide straight in.
This is the "MOD LIST" (it will grow)

1. 1.6D BOSH fuel pump bracket needs to be modified to fit on 1.9TD engine.
2. 1.6D sump needs to be put on 1.9TD engine.
3. 1.6D oil pump and collector needs modding to fit 1.9TD engine.
4. 1.6D fly wheel needs to go on to 1.9TD
5. New clutch kit (well why not)
6. TD exhaust system needs to be fitted.
7. Sump needs modding to fit turbo oil return.
8. alternator bracket needs fitting.
9. cooling system needs modding to fit 1.9TD engine.

When I have the engine in my possession and on the borrowed engine stand I will get some PICs on the thread.
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dubberatlast
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PostSubject: Re: T3 1.6D to 1.9TD convertion   Tue Jul 21, 2009 1:11 pm

get some bloody PICS up lol, you got some of the van minus a head so post um, i will get gunge to spank you else
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nomates
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PostSubject: Re: T3 1.6D to 1.9TD convertion   Tue Jul 21, 2009 5:15 pm

nice one carl ........



PIC'S
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Mr Scoops
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PostSubject: Re: T3 1.6D to 1.9TD convertion   Tue Jul 21, 2009 5:27 pm

Have you got an engine stand?? If not I have one you can borrow.

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The G
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PostSubject: Re: T3 1.6D to 1.9TD convertion   Tue Jul 21, 2009 6:22 pm

Mr Scoops wrote:
Have you got an engine stand?? If not I have one you can borrow.

Cheers scoops The chap I'm buying the engine off of said I could borrow one he has.
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The G
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PostSubject: Re: T3 1.6D to 1.9TD convertion   Tue Jul 21, 2009 7:44 pm

OK Here's some pick's of the 1.6D engine in bits. (just for Carl.













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The G
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PostSubject: Re: T3 1.6D to 1.9TD convertion   Thu Jul 23, 2009 8:57 am

OK well its slow still planing.
The engine that I can get easily is a 1.9TDi engine code AHU.
This means I have to find a dona MK3 golf TDI so that I can steal the loom and ecu.
I will also need to get an inter-cooler from a merc sprinter.

If any one knows of a golf for scrap let me know.
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dubberatlast
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PostSubject: Re: T3 1.6D to 1.9TD convertion   Thu Jul 23, 2009 9:43 am

The G wrote:

This means I have to find a dona MK3 golf TDI so that I can steal the loom and ecu.
I will also need to get an inter-cooler from a merc sprinter.

If any one knows of a golf for scrap let me know.

Not if you change the fuel pump to the aaz pump, and i dont run a intercooler Suspect
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Mr Scoops
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PostSubject: Re: T3 1.6D to 1.9TD convertion   Thu Jul 23, 2009 11:29 am

Dont listen to Carl, strap an intercooler on there.
Very Happy
he's just worried you'll whoop his ass up the dual carraigeway!

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HRD
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PostSubject: Re: T3 1.6D to 1.9TD convertion   Thu Jul 23, 2009 11:31 am

funny i wuz thinking the same thing tongue
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dubberatlast
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PostSubject: Re: T3 1.6D to 1.9TD convertion   Thu Jul 23, 2009 11:47 am

HRD wrote:
funny i wuz thinking the same thing tongue


Shoosh you two, he dosnt need a intercooler Very Happy
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The G
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PostSubject: Re: T3 1.6D to 1.9TD convertion   Sun Jul 26, 2009 11:18 am

OK scrap that Idea.

I have just bought a 1.9D normally aspirated no fuss engine.
185.00.
All I have to do is change the sump, oil pump, oil pickup and fit a spigot bearing.

This will gain me an extra 10 BHP on my old one and will just fit with loom messing.

i KNOW i KNOW it's the easy way out but if I go down the TDi route I would have to get the gear box modded to cope with the low torque engine. and to have it run properly and eficantly would need loom, ecu, oil cooler, intercooler, ect ect.
I would be up for the challenge if I had the donna car and cash to spend on it and a second car.
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The G
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PostSubject: Re: T3 1.6D to 1.9TD convertion   Sun Jul 26, 2009 11:28 am

Well I spent some time yesterday morning with the help from my youngest son Harry removing whats left of the 1.6D.

First I labeled up all the wiring ends.

Then I disconnected the water system from the engine.
Removed all the bolts holding the gearbox to the engine.

Then Harry removed the engine mount nuts and bolts with some help.
With a trolley jack supporting the engine from underneath I was able to separate the engine and gearbox and lower it to the floor.

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The G
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PostSubject: Re: T3 1.6D to 1.9TD convertion   Sun Jul 26, 2009 11:36 am

Things to purchase to complete the install.

Sump gasket.
Crank sprocket bolt.
Exhaust manifold gaskets.
Rocker cover gasket.
Inlet manifold gasket.
oil filter.
Spigot bearing.
Lock tight.

The interior is also going to be redesigned due to No 3 child on the way Very Happy And the seam rust but I might put them as two new threads.

Engine arrives on Thursday all tested. happy dayz
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dubberatlast
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PostSubject: Re: T3 1.6D to 1.9TD convertion   Sun Jul 26, 2009 11:50 am

Keep it under one thread mate, its easier to keep track, Congrats to you and jane on the baby front to Wink
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The G
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PostSubject: Re: T3 1.6D to 1.9TD convertion   Sun Jul 26, 2009 12:04 pm

Cheers bud
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