mrj
Posted a lot
Posts: 1,662
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Dec 26, 2010 18:09:13 GMT
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managed to find some time today for the workshop... first we had to fabricate a water hose for the engine ..... hmmm..... take one passat seat base : cut a corner off ... yes, works fine .... the thing underneath the "adaptor" is the crank case breather, which is not the same as on the Diesel block ... next was the petrol tank : we replaced it and all the hoses above the tank, not a nice job .... you can also see the Webasto heater, which we have to take off... then we mated gearbox and engine together ... new gear box mount ... the old one was totally gone ... new starter, ebay bargain, 70 € new... Ruben started on the loom; i am not an electrician at all (lights go out when i walk by) it was clearly his job ... 50% is not needed, like headlights wiring from the donor car... i was building the fuel pump bracket in the mean time ... the clamps came from the B&Q, they are used inhouse for water pipes .... the rubber/metal mount on the bottom is from the old exhaust ...welded together, painted, done ... the same was built for the fuel filter ... the fuel pump was wired up... the wires and the fuel lines were hidden in the chassis rail... and again, this was a half days work.... tomorrow i'll buy some more needed stuff (fuel hoses, bolts,power steering pump and a belt) , Ruben is trying to sort the wiring out and in the afternoon we could have the engine in ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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Thanks for keeping us updated - I'm storing all this mentally as I'm helping a friend do this swap. He's going from a 2.1 DJ though, so I imagine some other bits will be different.
I don't think his conversion will be as "clean" as yours though!
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mrj
Posted a lot
Posts: 1,662
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Dec 27, 2010 18:00:38 GMT
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Thanks for keeping us updated - I'm storing all this mentally as I'm helping a friend do this swap. He's going from a 2.1 DJ though, so I imagine some other bits will be different. I don't think his conversion will be as "clean" as yours though! thanks for the comments ! If you are doing the conversion from a DJ it is a lot easier, as you only have to change the gearbox (or the bellhousing and the drive shaft), the 2E engine i think also has the same injection system as the DJ, so should be easy ... i am trying to do that as nice as possible for two reasons : - it will be used by a young family (Ruben will become father this month), so it has to work - we have to have these changes approved by the TÜV, so the nicer it looks, the easier this will happen. and i don't want to have this thing break down every week, i prefer it to be bullet-proof today we did some work : the engine is in .... tight fit, but enough space between chassis rail and airflowmeter ... looks like it was there from factory... ;D we have to change the dipstick, adapt the throttle cable and the biggest concern, the air filter. I could use an unversal K&N unit, but then the TÜV might want to test the noise/loudness; especially as it is now a truck and will be a passenger car later; with the original filter we could get away without the expensive test . We'll find that out tonight and decide afterwards. Ruben is sorting out the loom tonight, so that we could wire it up tomorrow. Whatever happens, it will be running this week you might spot some rusty areas on the bus, those will be sorted by someone else in spring.... and, as you can see, the springs and shocks are badly corroded and have to be replaced by some better protected H&R ones
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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some pics from the last days : wiring loom sorted ; some smaller mistakes were found ... this is only a temporary loom, it will be shortened and insulated as soon as possible .... plan was to get the engine running, would not be nice if you have a proper loom and have to cut that up again .... also a temporary solution; a modified throttle cable... whilst a K&N 57i is on order, we had this ghetto air filter system.... ;D the coil was killed soon, they seem to be prone for that, though that was from 1996... we replaced it with another one from 1996 ;D A new one is on order, i was really astonished, that Ruben didn't already buy one, there were so much new parts bought .... so yesterday we tried to get the engine running, it started, but was not running properly ... a huge air leak from the brake servo and a wrong firing order were obstacles, but solved within minutes. Engine sounds really nice, but is far too loud for a comfortable driving and for the TÜV. Obviously the exhaust has not enough dampening inside, which makes sense, when you consider, that it it an exhaust for a turbo engine; the turbo reduces a lot of noise. Fitting a turbo is not an option here ;D, so i hope it will get quieter, when we fit the catalytic converter ... as mentioned above, the induction noise is ridiculos, i hope the K&N sorts that out, there is no space in the bay for the factory airbox without taking the battery out .... but i think we have to use the VW airbox for TÜV... first test ride today brings up another problem (which we already knew and the solution is being prepared right now); the gear box is far too short for that engine, so a 5speed is a must. Top speed was almost 100km/hs with a noise of a DTM V8 ;D But you have wheelspin in third gear ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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excellent write up jurgen!!! i,ve got more or less the same engine waiting to go into my doka! but mine is a rebuilt 1.8 from a mk2 gti digifant. I'm desperate for an airflow meter tho, so anyone reading this that has one spare , give me a pm please.
on the exhaust side, maybe a 1.6 silencer would a bit quieter, and on the throttle cable front, what you need is a product called a gripple, very good little wire connector that tightens as its pulled.
I'm interested to see the ridiculous acceleration on mine when i throw the gti in. mines a 1.6 n/a deisal!!! should be right lark on the journey to work(untill i blow the box, the only way the other half will realese the funds for a new one!!)
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"quote hairnet"
I'm not paying nine pound for a pi$$!
[/quote]
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mrj
Posted a lot
Posts: 1,662
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excellent write up jurgen!!! i,ve got more or less the same engine waiting to go into my doka! but mine is a rebuilt 1.8 from a mk2 gti digifant. I'm desperate for an airflow meter tho, so anyone reading this that has one spare , give me a pm please. on the exhaust side, maybe a 1.6 silencer would a bit quieter, and on the throttle cable front, what you need is a product called a gripple, very good little wire connector that tightens as its pulled. I'm interested to see the ridiculous acceleration on mine when I throw the gti in. mines a 1.6 n/a deisal!!! should be right lark on the journey to work(untill I blow the box, the only way the other half will realese the funds for a new one!!) thanks for the comments; if the air flow meter from the MV water boxer engine would be an option (it is also a Digifant), i have one spare ... i'll have to check that, but i remember changing it on my transporter, as the resistance from the airintake temp sensor was faulty ; after measuring both they had the same, so it should be working ... the 1,8 is a good engine and would also be a good choice, though we would struggle to get the Euro2 tax with that engine, so we went for the 2.0 .... we have an emission based road tax over here, a 2.0 with Euro 1 is about 280 Euros/year, a Euro 2 is half of it. If you don't have a catalytic converter , then it'll be around 500 Euros/year. Currently the transporter is registered as a truck, it costs about 150 Euros/year, as a passenger car with a 1,7 Diesel it would be around 700 Euros... well, back to the build : as we are still waiting for the air filter, i made a shield for it; as it would sit very close to the exhaust, we wanted some cold air. The back plate from an old washing machine came in handy, as it is zinc plated sheet metal. So i made this panel, cut a hole for the air intake and the intake temp sensor . i checked also my Webasto box, i have some spare water hoses which came with webasto heaters, i tend to keep that stuff, you might need it one day. The black plastic pipe is from a sharan, it just needed a hose for the crankcase breather; one of those Webasto hoses was ok, but needed an adapter, as it had the same diameter. So i took this : cut off a piece and used that as adapter... ;D In the meantime Ruben took out the loom, shortened all the wires and insulated them . I couldn't do much,so i made a bracket for the coil : Ruben wanted to have the coil closer to the fusebox, as he didn't want to modify the loom for the coil; well, it is his car, i don't think the place is suitable for the coil, as it sits very close to the exhaust manifold. But i made a little heat shield to the coil. To prove, that they are prone of being broken, i killed it with a hammer Well, he wanted to buy a new one anyway ... now he must ;D For the bracket the washing machine sheet panel was used ... Just to get an idea, how time consuming this wiring loom is; while Ruben was modifying it, i was rebushing a Passat subframe, two whishbones and suspension top mounts ... and also, while i had the engine crane, i fitted this engine in the Jetta : we continued today and he was finished with the loom : that was the old fusebox for the glow plugs; we relocated it under the rear bench and it houses the fuel pump relais and the ECU relais now... the ECU is on the right, the immobilizer in the middle. The immobilizer is also a "small" problem; a lot of Type 25s get stolen over here, so an immobilizer is a nice thing, but: the engine came with the ECU and ONE key . And no code for the key, so it will be hard to have another key made ... On most conversions over here people use the factory transporter loom/fuse box AND the fuse box from the donor car. That obviously works but we want to make it proper. Just like it could have been from the factory, but that is very time consuming. Some good news, too : the gearbox will be ready next week, so if all goes to plan, it will be ready on the weekend ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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Retro_Will
Part of things
A parcel shelf has meny uses....
Posts: 100
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nice tidy instalation there MrJ, you should be proud it looks factory
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1977 Morris Marina Van [don't ask], 2005 Sym Shark 4v [CVT Trouble], 2002 Yamaha SR [SOLD]
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Jan 10, 2011 13:45:22 GMT
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village
Part of things
Always carries a toolbox. Because Volkswagen.......
Posts: 567
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Jan 13, 2011 14:10:10 GMT
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If (and it's a big "if") the immobilser is of the same type as the one fitted to the T4 Transporter (chip in key and an unduction ring thingy around the ignition key barrel) the chips can the cloned by a key cutting shop.
I had a new key cut for our 800 Special at Timpsons, although I'm not sure if they have any branches in Germany......
HTH
Pete
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"The White Van is strong with this one...."
Chris "Chesney" Allen 1976-2005 RIP
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mrj
Posted a lot
Posts: 1,662
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Jan 13, 2011 20:51:41 GMT
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pete : that's a good idea, we'll give that a try at a cutting shop, maybe that works... well, back to work; i was alone today in the workshop, as Ruben apparently became father and he had to stay with his wife. What a lame excuse I wasn't really in the mood for the workshop, but i wanted to finish that "airbox"; we have two opinions about that, so as he wasn't here today i had to decide :-) as you can see, the hole for the hose was too large/slightly in the wrong place, so i added a piece of a door rubber in there, done. Also that cone filter was bolted to the body, so no water can be sucked in, as the filter is not on the bottom of the rear corner ... in the right you can see that i had to modify the panel to hide the wiring loom that goes to the airflow meter ... i took some Sika, sealed the panel (and most parts of my hands...) and bolted it on. Now we have an almost airtight panel , which should secure less induction noise and a lower air temperature . A better solution would have been to use the original airbox from the Golf, place it in the right corner of the engine bay and relocate the battery. But again, Ruben wants it that way and i am sure he'll have a problem with the noise when going to the TÜV. And yes, the fuel hoses are not staying like that ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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DutyFreeSaviour
Europe
Back For More heartbreak and disappointment.....
Posts: 2,944
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Jan 14, 2011 11:54:11 GMT
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Top work Jurgen..... is this now ready for TüV? A really tidy conversion. On the TüV note - why would noise be an issue on intake? I can understand loud exhaust - but do they measure intake too?
(Sorry fella - I always passed my German motors on to Babette's folks to have 'em tested - I've forgotten).
John
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Back from the dead..... kind of
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mrj
Posted a lot
Posts: 1,662
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Jan 14, 2011 18:40:37 GMT
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Top work Jurgen..... is this now ready for TüV? A really tidy conversion. On the TüV note - why would noise be an issue on intake? I can understand loud exhaust - but do they measure intake too? (Sorry fella - I always passed my German motors on to Babette's folks to have 'em tested - I've forgotten). John hi John, it is almost ready for TÜV. Two parts missing : the correct gearbox and a catalytic converter The TÜV is testing the noise when you drive by at a certain speed. They do not have to check that, but they certainly will, when they hear it ;D They mostly do that on an engine conversion, but as the transporter changes from "truck" to "passenger car" in the papers, they have to, as they have different settings . So "truck" can be louder as "passenger car" .... we did a little stuff today, finished most of the wiring, replaced the stereo speaker cable at the fuel pump to correct cables and started it up (with a new coil, #3 now..) .... it is still very loud, induction noise is very nice and subtle, so i hope that the catalytic converter brings the noise down. Otherwise Ruben must buy a proper exhaust .... tomorrow is the next test drive, and time to clean up the workshop, looks like a civil war happened there. Almost
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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Feb 20, 2011 21:01:59 GMT
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this weekend we changed the gear box.... my mate has bought a freshly rebuilt 5speed box with switchable LSD ... it has all the goodies inside, long final gear , new bearings etc... traction is sometimes a problem on a type 25, especially on wet grass or when you get stuck in a ditch in scotland , that's the reason for the LSD ... the mechanism to switch it on/off was taken from the syncro transporter, here with new stainless steel brackets. The switch will be from an Audi quattro ... the switch with the wire is for an indicator, if the LSD is on/off ... to prevent seizing of the mechanism of the diff, we added a rubber hose filled with grease ... we also have the possibility to connect a gearbox cooler, but as the transporter won't be used for serious off-roading, it might not be necessary ... i am not a big fan of removing gearboxes from cars, but on the type 25 it is one of the easiest things to do. With proper tools and two mechanics, you can get it in and out under two hours ... not in this case, as we had to change the crankshaft seal ; Ruben bought a new one before we changed the engine, but it was the wrong one, so this was the perfect time for the correct one ... by the way, i use used latex gloves to cover the driveshafts; so no grease everywhere when the box is out : then we cleaned up the gearbox mounting bracket, painted it and sandblasted the point, where the ground wire is attached ... ready to go in : almost.... this was when it went wrong, you would expect a proper bracket when you spend almost 2K € on a rebuilt box from a transporter specialist... well, he had a bad day, as the bracket was from a 4speed box and it wouldn't clear the frame ..... so we modified it : the rubber part had to move backwards 3 centimeters, so we cut off some metal and drilled new holes ... one bolt was placed in an old hole for the ground wire ... and it fits ... ! this is not a permanent solution, we'll be fitting the correct bracket as soon as possible, but it was sunday, no way to find a bracket and the car was needed and i need my workshop next week, too ... first test drive was ok, it is total different now ... when the old box reached the vmax at 95km/h , it was easily possible to go up to 145 km/h today , we didn't try more due to the weather conditions on the (private) road ... all that is left now is change the gearstick and have some adjustment on the mechanism itself . Then the height issue will be solved, the power steering fitted and so on ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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bmboy
Part of things
great age!
Posts: 180
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Feb 22, 2011 21:22:41 GMT
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Excellent work. You sir, have earned a bookmark!
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Skoda Estelle 120l x3 Skoda Favorit Triumph Dolomite Mercedes-Benz 190E BMW 635csi BMW 528I Volvo 850 Mercedes-Benz 230TE Skoda 136 Rapid
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mrj
Posted a lot
Posts: 1,662
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small update : three-spokes ! and AT tyres, what a strange combination... hmmm..... not sure .... we welded in the brackets for the Multivan bench : now he will fit the Bluestar interior, the Bluestar was a special edition with a very nice and comfy interior ( and rock'n'roll bed ) ...
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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Apr 13, 2011 19:21:23 GMT
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Love it! ;D
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1984 Subaru GLF Hatch 1983 Skoda 120LE Super estelle 1977 Subaru DL Wagon 1978 Datsun 120Y Coupe 1995 Skoda favorit estate
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mrj
Posted a lot
Posts: 1,662
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Jun 19, 2011 12:11:26 GMT
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well, small update here : Ruben since then found a TÜV engineer who looked over the conversion and gave his ok; now it is officially and legally in the papers ... it is running fantastic and reliable for a couple of kilometers now without trouble. Only thing is, the gearbox gearing is killing most of the power, so instead of changing the gearbox again, he bought a VR6 engine, that has been fitted already in a Type 25.... so almost plug&play, stay tuned, we start the conversion in about 4 weeks time .... the conversion will be straight forward, but we have to change the brakes , too , the original brakes are tested up to 150 BHP, so there will be an update with bigger disks at the front and a conversion from drums to discs at the rear ...
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Last Edit: Jun 19, 2011 12:12:10 GMT by mrj
- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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Jun 23, 2011 19:43:25 GMT
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today the next engine arrived ;D some nice and some strange modifications; this engine came out of a Type 25, so it is almost plug&play.... a neat mod was the closed circuit of the power steering pump ;D Instead of modifiying the belt drive, they just connect in/out of the pump ... easy for us, as Rubens van will have power steering once we're finished... that is the two-fusebox-system, where you keep the fusebox from the donor car and hook it up to the existing electric system on the car. Of course this is nit what we want, Ruben will cut this out and make a separate loom which will be connected to the vans fusebox....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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Jul 29, 2011 20:23:43 GMT
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today we started, after a couple of strange jobs i did to other cars in the last weeks this was very pleasant... engine out didn't take that long : engine was separated from the gear box and put on a pallet, ready to be collected soon to a new home ... drained the gearbox , as we have to change the bell housing and the drive shaft into the gearbox ... not sure about the amount of metal in the rebuilt box this is a diesel bell housing, we need a petrol one ... at twelve o'clock you see the driveshaft, which needs to be changed to boxer engine spec ... left to the drive shaft there is a black metal panel; that was a factory fit to the south african gearboxes, it helps that the oil acutally comes to the diff, this is a must conversion if you have lots of torque/power from the engine .... removing the drive shaft was a pain.... on top we have the diesel driveshaft, on the bottom the petrol one .... the drive shaft is bolted to the inner driveshaft and secured with the sleeve, which is secured with a spigot ring... on a non-LSD gearbox an easy job, but this one has an LSD , and therefore not easy .... it was a bit late tonight, so tomorrow we'll continue ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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Jul 30, 2011 20:19:45 GMT
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a new day and the driveshaft problem was solved : then the bellhousing was cleaned and prepared : of course a new gasket for the driveshaft was fitted ... new bronce bearing for the starter ; wibblepoo pic ... bolted up and ready to be mated to the engine. The engine was lifted onto a small workbench ... the mess with those water hoses will be solved properly .... and it fitted .... on the left there is a blue plastic box, which is the vacuum actuator of the LSD, we needed to turn that upside-down to make clearance for the starter ... ready to go in, just a trial fit, as we need to take some metal away from the engine bay; also some rust needs to be adresses and two panels welded up; after that the engine bay will be painted and the engine goes in... this is the coil pack, it sits at the back of the engine, we need to buy a new one and fit that on a different location, otherwise we would have to cut away a lot of metal... will it fit ? ;D the funny power steering pump arrangement will be changed of course ... tight fit ... but it is in we need to build a frame for the new (higher) engine cover though ... a little bit of metal has to be cut away at the rear and a bit at the front ... all in all it is not too bad ... we pushed the engine out again, but to find the correct position we did this :
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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