T25 Alternative Engine Forum

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Most liked posts	Author	Posted	Liked	Forum
1.9 AAZ engine	mrhutch	26 May 2026, 10:11	Once this week	T25 Alternative Engine Forum

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Last post

Petrol Alternative Engines...

Last post by silverbullet « 06 Apr 2024, 16:09
Replies: 10
by HarryMann » 15 Oct 2005, 01:57

Subaru Engine Types and Options

The normally aspirated (NA) flat 4's weigh about the same as a WBX and after installation there's always a cleaner...

10 Replies

130272 Views

Last post by silverbullet
06 Apr 2024, 16:09
Diesel Alternative Engines..... Read before asking questions

Last post by sdelasal « 09 Aug 2008, 22:43
Replies: 18
by admin » 13 Oct 2005, 09:35
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VW are renowned for their diesels and those fitted as standard to the T25 do not do it justice. What can you replace them with to getting better...
18 Replies

201246 Views

Last post by sdelasal
09 Aug 2008, 22:43
EJ20 Engine Overheating - Solutions?

Last post by Basilakios « Yesterday, 16:35
Replies: 25
by Basilakios » 12 May 2026, 15:20
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Last year I bought my T25 which has an Subaru EJ20 engine conversion. I don't know much about the engine but it was done by Steph at Mac VW and I...
25 Replies

5786 Views

Last post by Basilakios
Yesterday, 16:35
AFN expert Needed - Cash waiting lol

Last post by 16vmini « Yesterday, 11:13

by 16vmini » Yesterday, 11:13

Money waiting for an AFN expert to come and get my AFN engine running again , it died as i driving it last year , i went through all sorts now ,...

0 Replies

52 Views

Last post by 16vmini
Yesterday, 11:13
1.9 AAZ engine

Last post by mrhutch « 26 May 2026, 10:11
Replies: 2
by dcworm57 » 24 May 2026, 07:21

I’ve recently bought a Syncro , it’s got 1.9 AAZ TD engine in it . The engine has had a full rebuild by a German firm in the last 12 months I have...

2 Replies

648 Views

Last post by mrhutch
26 May 2026, 10:11
Ford Mondeo st220 into '88 Caravelle

Last post by R0B « 22 May 2026, 13:12
Replies: 78
by Dueller » 04 Jul 2023, 20:40
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Starting this thread to document my thoughts and journey here, hope it helps someone else who's having some ideas but not jumping in for whatever...
78 Replies

422000 Views

Last post by R0B
22 May 2026, 13:12
AAZ hot starting problem

Last post by colinthefox « 20 May 2026, 21:05
Replies: 3
by morganite » 19 May 2026, 12:21

AAZ engine, just rebuilt the engine, rebuilt injector pump,injectors, glow plugs,fuel line with non-return valve,Starts first turn when cold, when...

3 Replies

483 Views

Last post by colinthefox
20 May 2026, 21:05
Coolant issues

Last post by mioba « 18 May 2026, 22:26
Replies: 12
by BarnyE » 28 Feb 2026, 13:59

Hi, I’ve been rebuilding my van for the last 12 months, it got delivered on a trailer and I’m almost ready for its first test.

But I’m having an...

12 Replies

17023 Views

Last post by mioba
18 May 2026, 22:26
Exhaust Heat Shield

Last post by mioba « 18 May 2026, 22:17
Replies: 2
by Burtybassett » 08 May 2026, 08:07

Morning all.

I need to make a heat shield for the exhaust on my 1983 Vanagon as I need to protect the engine from the heat.
This is a Tdi...

2 Replies

909 Views

Last post by mioba
18 May 2026, 22:17
Replacement intake/throttle seal

Last post by Aidan « 16 May 2026, 15:11
Replies: 4
by Nelpy » 24 Jun 2024, 18:37

One for the Subaru people

I'm looking for a new seal for where the air intake attaches to the throttle body as pictured. It is a 2001 Legacy H6...

4 Replies

29805 Views

Last post by Aidan
16 May 2026, 15:11
Replacing EJ22

Last post by silverbullet « 14 May 2026, 06:44
Replies: 3
by mariner » 10 May 2026, 20:39

Hi all. I'm considering replacing my Subaru engine for a newer version and would be interested in people's thoughts and opinions.

I bought my van...

3 Replies

1176 Views

Last post by silverbullet
14 May 2026, 06:44
Starter bolts for a 1.9D

Last post by shampooefficient « 11 May 2026, 07:53
Replies: 2
by shampooefficient » 10 May 2026, 17:17

Currently persuading new lump into old engine bay.

Got the engine hung and gearbox bolted on. Trying to fit the refurbed starter from the original...

2 Replies

1191 Views

Last post by shampooefficient
11 May 2026, 07:53
1.9 AAZ engine manual

Last post by hubcap61 « 06 May 2026, 15:09
Replies: 4
by dcworm57 » 05 May 2026, 16:22

Just picked up a van it has. 1.9 AAZ TD engine . Which manual do I get that covers this engine , Bentley or is there another ?
cheers

4 Replies

1771 Views

Last post by hubcap61
06 May 2026, 15:09
Black smoke on acceleration.

Last post by silverbullet « 26 Apr 2026, 20:00
Replies: 8
by DarrenC90 » 11 Apr 2026, 19:10

Hi all, thanks for any help in advance.
So 1.9TD Aaz vanny. Replaced head gasket, valve stem seals, injector nozzles (pop tested to within 5bar or...

8 Replies

4752 Views

Last post by silverbullet
26 Apr 2026, 20:00
Type one engine instead of CT?

Last post by R0B « 22 Apr 2026, 09:14
Replies: 55
by fall-apart-dave » 07 Apr 2011, 18:19
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Has anyone ever put a type one engone into a T25 in place of a CT?

I have found a few sites that discuss the details, and am confident that the...
55 Replies

30557 Views

Last post by R0B
22 Apr 2026, 09:14
2.0 MkIII golf GTI engine swap - wiring

Last post by Aidan « 13 Apr 2026, 07:34
Replies: 1
by MissSpentYouth » 10 Apr 2026, 20:02

Hi All,

Just doing some research into a 2.0 mkIII golf GTi engine swap into a T25.

The mechanical side seems well documented and appears...

1 Replies

2393 Views

Last post by Aidan
13 Apr 2026, 07:34
Injector thread broken off on cylinder head (engine). What now?

Last post by meeh85 « 12 Apr 2026, 16:35
Replies: 9
by meeh85 » 10 Apr 2026, 09:43

Hi.
Greetings from Norway. I will try to explain in english..... :) And thanks a lot for reading this !!!

I have a 1989 VW T3. It’s supposed to...

9 Replies

4509 Views

Last post by meeh85
12 Apr 2026, 16:35
Headache trying to bleed my fuel pump

Last post by axeman « 06 Apr 2026, 16:54
Replies: 5
by aimlessrock » 05 Apr 2026, 07:39

I changed the fuel filter in my van (1.9 AEF diesel) and I just can’t get the van to now start.

Any tips on how to best bleed the pump?

Thanks

5 Replies

2507 Views

Last post by axeman
06 Apr 2026, 16:54
Temp sensor retaining clip hell(p)

Last post by redsnapper « 04 Apr 2026, 19:41
Replies: 17
by redsnapper » 31 Mar 2026, 17:10
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Hi all,

Not posted on here for a long time but regular browser for solutions but can't find an answer to this and feel I am just being an idiot

1Y...
17 Replies

7450 Views

Last post by redsnapper
04 Apr 2026, 19:41
TSR engine conversions question

Last post by mrhutch « 27 Mar 2026, 15:48
Replies: 2
by Swordfish93 » 27 Mar 2026, 08:00

Has anyone used them recently? I see bad reviews from quite a few years ago and want to know if they have changed there ways or not

2 Replies

23605 Views

Last post by mrhutch
27 Mar 2026, 15:48
Which gearbox.

Last post by cobblers « 14 Mar 2026, 15:47
Replies: 5
by HappyCamper » 13 Mar 2026, 13:24

Hi, Anyone know what the best gearbox would be best to run with a golf agg engine. I'm presuming the original 1.6 diesel box will be too low gearing,...

5 Replies

29531 Views

Last post by cobblers
14 Mar 2026, 15:47
T25 Engine Swap HELP...

Last post by Stesaw « 04 Mar 2026, 13:16
Replies: 27
by monsterVW1982 » 18 Apr 2011, 10:09
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Hi all,

After a little bit of advise with selecting a new enginer, gearbox and a turbo for my van after the current engine give up the ghost on the...
27 Replies

72751 Views

Last post by Stesaw
04 Mar 2026, 13:16
oil pump/vacuum pump problem

Last post by Aidan « 02 Mar 2026, 18:55
Replies: 2
by morganite » 28 Feb 2026, 21:21

Hi, need some help please! AAZ conversion, lost the oil pressure because the new 2,000 ml 1.9td oil pump male tang was,nt reaching into the female...

2 Replies

13978 Views

Last post by Aidan
02 Mar 2026, 18:55
AHU turbo question

Last post by hotpod « 27 Feb 2026, 15:46
Replies: 9
by hotpod » 12 Feb 2026, 10:56

I have an AHU engine with a KKK turbo which has a pipe from the compressor to the N75 and one from the N75 which goes back to the turbo to operate...

9 Replies

26737 Views

Last post by hotpod
27 Feb 2026, 15:46
Whining when accelerating

Last post by peteandnero « 25 Feb 2026, 16:43

by peteandnero » 25 Feb 2026, 16:43

Hi,
my AFN TDI conversion 5 speed Westfalia has recently developed a new sound. When accelerating in 4th or 5th there is a woooo type noise which...

0 Replies

23079 Views

Last post by peteandnero
25 Feb 2026, 16:43
1y identification

Last post by davidoft1 « 12 Feb 2026, 10:47
Replies: 9
by BarnyE » 08 Feb 2026, 10:16

I have a 1900 1y conversion in my van and want to do a belt change on it.
Unfortunately I don’t know the source of the engine. I’m looking at serial...

9 Replies

26009 Views

Last post by davidoft1
12 Feb 2026, 10:47
CS to AGG engine swaps

Last post by cobblers « 30 Jan 2026, 09:06
Replies: 2
by HappyCamper » 29 Jan 2026, 18:54

Hi, I was looking for info, on changing a CS diesel engine for an AGG. There seems to have been plenty done, but I can't see much info. I've tried...

2 Replies

19185 Views

Last post by cobblers
30 Jan 2026, 09:06
Which petrol engines.

Last post by axeman « 16 Jan 2026, 17:44
Replies: 9
by HappyCamper » 09 Jan 2026, 13:56

Hi, a few more questions on engine swaps. I've seen info on swapping from diesel to petrol. The good thing is I'm more comfortable working on petrol...

9 Replies

34370 Views

Last post by axeman
16 Jan 2026, 17:44
1.9 Tdi upgrade , issues , solutions

Last post by HappyCamper « 08 Jan 2026, 11:14
Replies: 10
by dcworm57 » 27 Nov 2025, 15:33

I’m considering 1.9 Tdi upgrade to my 1.6jx westy . It’s now on Brickwerks high lift kit and I’m told by various sources that 1.9 Tdi wont work on...

10 Replies

32579 Views

Last post by HappyCamper
08 Jan 2026, 11:14
Diesel Injection Pump.

Last post by lefty67 « 18 Nov 2025, 19:17
Replies: 1
by Burtybassett » 15 Nov 2025, 16:49

Hiya 👋

Does anyone know of anyone that would/can refurb a Diesel Injection Pump ?
1.9TDi - AHU Engine
Think it's a Bosch pump - 028 130 115 M...

1 Replies

21832 Views

Last post by lefty67
18 Nov 2025, 19:17
Re-mapping AHU TDI

Last post by ZsZ « 30 Oct 2025, 14:37
Replies: 14
by hotpod » 02 Sep 2025, 13:25

Is this possible?
When I put the engine in 12 years ago, I thought I could get it re mapped ( because it has an ECU) to suit pushing a Syncro Westy...

14 Replies

46455 Views

Last post by ZsZ
30 Oct 2025, 14:37
Coolant Type for Subaru EJ20 Engine Conversion

Last post by Basilakios « 24 Sep 2025, 12:13
Replies: 7
by Basilakios » 17 Sep 2025, 11:45

Another week and another new problem to deal with.

I've not had this T25 campervan for long and barely driven it anywhere due to an ongoing issue...

7 Replies

40778 Views

Last post by Basilakios
24 Sep 2025, 12:13
AAZ diesel pump leak

Last post by Al Housman « 13 Sep 2025, 20:28
Replies: 5
by Al Housman » 13 Sep 2025, 14:58

The truck is finally going after being stood for about 2 years and sounds really good.

There is however a steady leak from under the diesel pump. I...

5 Replies

35012 Views

Last post by Al Housman
13 Sep 2025, 20:28
AFN TDI Obd scanner

Last post by Robsey « 07 Sep 2025, 20:53
Replies: 3
by fh9977 » 04 Sep 2025, 12:31

Hi, would anyone be able to recommend an OBD device I can connect to the port of an ATF TDI engine to read live data? Is it possible to have a...

3 Replies

33819 Views

Last post by Robsey
07 Sep 2025, 20:53
Retro fit engine from a Golf GTI to a 1.9

Last post by Ukjamie82 « 04 Sep 2025, 13:00
Replies: 5
by Ukjamie82 » 02 Sep 2025, 06:09

Good morning all

I am in the throws of retro fitting a 1.9 water cooled engine from a 1.8 Golf GTI , reason , ecu failed and could not find a...

5 Replies

35618 Views

Last post by Ukjamie82
04 Sep 2025, 13:00
T25 legacy conversion wiring loom issue

Last post by ManicGTI « 03 Sep 2025, 21:13
Replies: 2
by Paul1981 » 27 Aug 2025, 20:37

Hi everyone
Please can anyone advice me on where i can source a wiring diagram for a 3 pin ECU connection from a Subaru Legacy. I’m not sure what...

2 Replies

33375 Views

Last post by ManicGTI
03 Sep 2025, 21:13
Help! Timing belt creeping off cog

Last post by colinthefox « 30 Aug 2025, 18:48
Replies: 8
by sopranolady » 26 May 2016, 09:36

Hi, apologies if this is the wrong category for the post, I'm looking for urgent advice, having hit a snag with our engine fitting project.

Our 1990...

8 Replies

40808 Views

Last post by colinthefox
30 Aug 2025, 18:48
Throttle Potentiometer Issue

Last post by TwinTurbo « 16 Aug 2025, 12:36
Replies: 6
by Nistorph » 21 Jul 2025, 20:40

Hi,

I’m looking for some guidance please.

I have a T25 fitted with a 1.9 AHU TDI lump. It now, with increased frequency, reverts to some sort of...

6 Replies

644543 Views

Last post by TwinTurbo
16 Aug 2025, 12:36
Part Identification

Last post by Oldiebut goodie « 13 Aug 2025, 14:01
Replies: 7
by Bison535 » 13 Aug 2025, 10:13

Early Bay T2 with petrol engine 1.6 has difficulty in running and suspect a ‘sensor’ fault!?! Have removed this Sensor Unit but cannot identify which...

7 Replies

38160 Views

Last post by Oldiebut goodie
13 Aug 2025, 14:01
Glow plugs T3 tdi

Last post by Simon Baxter « 11 Aug 2025, 13:10
Replies: 3
by Kougar38s » 24 Jul 2025, 10:56

Hi all, I'm a new member and a new owner of a 1989 T3 tdi 1.6.
I wonder if any one can help with a problem I'm having. Its only just started. The...

3 Replies

37046 Views

Last post by Simon Baxter
11 Aug 2025, 13:10
1.9DG to diesel swap.

Last post by DavidS « 10 Aug 2025, 21:37

by DavidS » 10 Aug 2025, 21:37

I used to own a T25 with a 1.7KY engine which not obviously not quick, but it was very reliable and pretty economical. I had planned to put a 1Y in...

0 Replies

52126 Views

Last post by DavidS
10 Aug 2025, 21:37
Cosworth 2.9litre in my Crewwy

Last post by dickspanner « 07 Aug 2025, 19:53
Replies: 302
by dickspanner » 04 Jul 2006, 15:56
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Hi folks

Not been on for a while but have just farmed through all V6 threads again.

I have gone and done it, I have bought the Granada Cosworth...
302 Replies

357757 Views

Last post by dickspanner
07 Aug 2025, 19:53
1.6d to 1y the definitive guide

Last post by JonathanUSSF « 30 Jul 2025, 10:50
Replies: 103
by weldore » 15 Aug 2012, 16:05
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theres been a few people over the years gone this route including myself and have had to ask questions or trawl through the alt forum for answers and...
103 Replies

743600 Views

Last post by JonathanUSSF
30 Jul 2025, 10:50
Power steering pump

Last post by Aidan « 27 Jul 2025, 09:14
Replies: 2
by paradox » 26 Jul 2025, 16:09

I’ve a 1.9 TDi Passat engine in my van
Despite fitting a new belt and making sure it’s tensioned correctly
It slips the belt and squeals at full...

2 Replies

360774 Views

Last post by Aidan
27 Jul 2025, 09:14
1.9d 1Y exhaust.

Last post by BarnyE « 26 Jul 2025, 18:37

by BarnyE » 26 Jul 2025, 18:37

Hey all, been reading up on this and I’ve got myself more confused than ever.

So long story short inherited someone else’s bodge of a conversion....

0 Replies

373780 Views

Last post by BarnyE
26 Jul 2025, 18:37
AAZ VS Air cooled

Last post by dcworm57 « 16 Jul 2025, 05:12
Replies: 6
by davegeezzer008 » 27 Jun 2025, 19:58

Im having problems getting my AAZ pump rebuilt as bosch don't make many parts for the VE pump any more, so I'm just thinking ahead about my options...

6 Replies

161581 Views

Last post by dcworm57
16 Jul 2025, 05:12
Engine swop question

Last post by colinthefox « 11 Jul 2025, 21:08
Replies: 1
by aimlessrock » 11 Jul 2025, 19:43

Hi,

I was looking at the engine in my t25 and noticed that someone has tipped the letters AEF on it.

It looks different to the pictures of the...

1 Replies

35392 Views

Last post by colinthefox
11 Jul 2025, 21:08
AAZ upgrade turbo and realistic power

Last post by syncroandy « 08 Jul 2025, 14:55
Replies: 1
by TommyJenko » 21 Jun 2025, 16:40

Hi guys I have a AAZ in bits that came with my van, I was going to rebuild it but looking at the turbo it’s a kkk-k03 which seems a bit small for the...

1 Replies

35809 Views

Last post by syncroandy
08 Jul 2025, 14:55
1.8T Sump Bolt Access

Last post by Vaughanylive « 06 Jul 2025, 07:43

by Vaughanylive » 06 Jul 2025, 07:43

I’ve got a 1.8T converted Syncro (AUM stamped block, but cable throttle) with a custom mild-steel sump made by whoever did the conversion. The paint...

0 Replies

56562 Views

Last post by Vaughanylive
06 Jul 2025, 07:43
AHU TDI Vibration Damper Pulley testing

Last post by hotpod « 28 Jun 2025, 08:52
Replies: 8
by hotpod » 31 Mar 2025, 15:29

Does anyone know how to test if the vibration damper pulley ( harmonic balancer) on the crank shaft is in good shape?
Mine drives the ribbed...

8 Replies

44490 Views

Last post by hotpod
28 Jun 2025, 08:52

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