Author Topic: hilshy n/a swap out/td swap in. (Read 6469 times)

Hillshy · « **on:** June 22, 2007, 10:43:29 pm »

so i after several attempts to pick a fair weather day to start the swap out, 2 wet weeks later i said £uck it, i cant cope with the great british weather. so i started rather late one afternoon. put the bus on ramps and dropped the engine n gearbox out which was always going to be the easy bit. In case you ask why the gearbox too? i had managed to get another 5spd box with a longer 5 gear, all other gears were the same.

first job: swap clutch off the n/a lump to new engine(only 8k miles on it.) then bolt the geabox to engine in 1 lump which makes for an easier install, 2 hours later! im only just installing the clutch. when i was removing the clutch i sheared the last bolt so i had to drill it out.

finally managed to sandwich them together and attempted to offer up gearbox n mount to the underside of the vanagon, i noticed 2 sets of bolt patterns- so i offered them on to the prevoius ones used. 3 of the 4 bolts went in no problem, last one snapped off- WTF, not again! so i decided to leave it for now come back to it later.

turned my attention to the engine mounts, 1st one in ok, second one went in but seems tight like it was on the piss, but it was in, so i let the jack off and hopped up to take a look from the top. to my horror, the whole drive train totally looked on the piss. 1 hour later i had it sorted, the new geabox was slightly different as was the mount and therefore i had to use the other bolt holes, this time all 4 bolts went in ok. hopped up again all it all looked square :lol: finally. i also had to change the rear half of the linkage (5 foot section) as per the different box. set up the linkage i can get all gears ok.

next job: plum in all the water works. also noticed the oil drain pipe on the turbo was leaking, so i gave it a slight tweak with a spanner, guess what? it snapped off!

that's as afar as i got....... bye for now :cry: :x

burn_your_money · « **Reply #1 on:** June 23, 2007, 06:22:54 am »

Ohh that is so frustrating. Hopefully you get it all taken care of without anymore hangups

Black Smokin' Diesel · « **Reply #2 on:** June 23, 2007, 09:31:50 am »

That sucks man. You always get hung up on small details.

jtanguay · « **Reply #3 on:** June 23, 2007, 09:46:57 am »

well those are good experiences... frustrating, but that's how we learn. i wonder if a little bit of heat & lube would have done that oil drain pipe some good...

good luck on your project!

stopping · « **Reply #4 on:** June 23, 2007, 11:34:09 am »

It might have been leaking because it was too tight!

Hillshy · « **Reply #5 on:** June 23, 2007, 04:34:19 pm »

Evening all,

fair comments, i always use plently of lube, even my wife complains. :oops: i totally agree with the getting hung up on small things, she also complains here!, its all about the small things. i dont think it was to tight to begin with. IF ONLY :wink: . i always try to plan ahead, G clamping the coolant hoses so not to lose all the coolant, as those who own/work on these will know, 17.5 ltrs off coolant is alot to loose and refill, i managed to keep it all except for the block contents, you cant have everything tho!

good progress today for the 1 hour i had!-replaced oil drain pipe from turbo,replaced oil as i had to drain off to replace pipe, rerouted diesel pipes connected them up, connected all the usual wires various guages, alternator and battery. connected the drive shafts and bolted em up, connected clutch. so fair bit done today.

i also managed to bypass the inlet pipe thus removing the intercooler(only temp measure!!!! dont worry not gone mad just yet!) and also put a loop back pipe on the the oil filer housing so im not under and pressure to find a location for the cooler until it suits me

reason for both so I could get it started which it did very quickly! and runs fine. so far!

still undecided where to locate oil cooler, and the intercooler and air filler?

exhaust came out well, made up 2.25in pipe from turbo to rear box, it should flow well, i hope!

jobs to do:

run 6 feet of EGT gauge wire under the vehicle and connect up.
run 6 feet of boost gauge hose under the vehicle and connect up.
find a suitable location for intercooler and oil cooler.
locate air filter.

thanks for your interest and your comments so far. keep you posted on progress, cant wait to road test. :wink:

burn_your_money · « **Reply #6 on:** June 24, 2007, 08:07:52 am »

You got alot done, right on. Do you have any pictures of any of this?

Hillshy · « **Reply #7 on:** June 24, 2007, 12:50:57 pm »

libbybapa, cool link just what i need, very very useful indeed.

there are other solutions out there but this is the only one where you dont have to change anything on the van itself, ie raising the coolant bottle or lowering the rad, so it gets the thumbs from me.

thanks again.

ps
no progress at all on the van today , Rain stopped play...Again! try again tomorrow.

burn_your_money, pics yes i do, uploaded- no! but i will over the next few days.
:oops:

Hillshy · « **Reply #8 on:** June 24, 2007, 10:43:33 pm »

just a passing thought. When I ran the engine for several minutes the other day, 2 things I noticed have been bugging me.

the van is currently on my drive with its arse in the air, as the rear is sitting on car ramps so this may be the cause for the first problem.

1/ one of the prev posts I mentioned I oil feed pipe from the turbo to the sump issue(snapped off). after i replaced it tho! i started the engine and lay underneath to see if i could see any oil leaking, i didnt. but i did notice a drip of oil coming out between the turbo and exhaust gasket. The turbo is new so i can't be that.

oil drip-
question: Do you think it could be the fact that the rear is elavated and the oil level in the sump is with a bias to the front of the sump, is the oil not draining out of the bottom of the oil drain pipe and therefore backing up in the turbo where some is dripping out?

smoke-
2/ when the engine is on tick over, if i give it a quick press on the gas pedal the revs climb and the turbo spools ok when i let it off as the revs drop i get cloud of grey smoke til tick over then it disappears again? I'm not worried but its the first week of actually having a turbo in my van so its all new to me.

question:im guessing its unburnt fuel? maybe because there's not real boost or load on the engine?

any theorys/opnions welcome?

knowtwodrugs · « **Reply #9 on:** June 25, 2007, 04:00:01 am »

Couldn't you run the intercooler and the oil cooler under the van? At least the oil cooler anyway, the IC might be a bit too much work. As for the air inlet I'm not sure I've never been intimate with a van. =) Where was the old one though? I would start there and ponder it.

Hillshy · « **Reply #10 on:** June 26, 2007, 02:58:09 pm »

burn_your_money · « **Reply #11 on:** June 26, 2007, 03:27:29 pm »

A 1.9 pump on a 1.6 block?

I like the color of the block, looks sharp

Hillshy · « **Reply #12 on:** June 27, 2007, 04:14:07 pm »

latest blog:

managed to get 3 hours work on the bus today, dodging between the wet n dry weather, its really not a good place to be at the moment, espically in the North midlands area - you may have seen in news about the really bad floods here in the uk, some places under 7 feet of water (not so near to me tho!):shock: . So as you can amagine its friggen wet here.

anyways- managed to get 2 jobs done from the list, running 9- 10(approx) feet of EGT wire and boost tube. Amasingly the length of EGT wire that came with my gauge reached all the way until ending just a few inches into the dif cutout above fuel tank. I opted to crimp the joints, then intombed them in a section of 20mm plastic tube which I sealed at both ends. Connected up the gauges- fired up the motor and badabing baby they actually worked

jobs still to do:
find a suitable location for intercooler and oil cooler.
locate air filter.

new jobs
fix leaky injector pipe
replace the new turbo :x - which is without doubt chucking oil into the exhaust and dripping between the exhaust gasket. :x

so near but still so far!

burn_your_money

cheers man, nice and green Im well happy how it came out!

the pump is a 1.6td.

Baxter · « **Reply #13 on:** June 28, 2007, 02:44:57 pm »

Cool.
I now keep replacement 1.6TD turbo-sump oil return lines on the shelf now, also for AAZ.
Just a thought..
Wheres the paint from? looks good that!

Hillshy · « **Reply #14 on:** June 28, 2007, 04:31:32 pm »

Hello mate.

ok that's good to know i may give you a call, how much out of interest?

the paint is the new range from hammerite, well - hammerite got bought out and a new range came out- cant think of the new range name? will check tomorrow! anyways the techie spec seemed like it would be ok to use on a block. tad dear tho! but im happy with the results.

need a kkk k14 turbo :cry: mines pissing oil into the exhaust? got any???

Author Topic: hilshy n/a swap out/td swap in. (Read 6469 times)

stopping

Baxter