Syncro engine swap - DJ to AGG

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syncropatrick
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Re: Syncro engine swap - DJ to AGG

Post by syncropatrick »

tforturton wrote:Did you have to tow the Syncro to your new place?
It was trailered to a vehicle storage for a 1 week stay, then delivered to me on back of 7.5t recovery truck, then pushed down the 100ft tarmac driveway to its spot right next to the garage. Cost me £125 all in using local peeps.
Wanted: offside part of full-height walk-through bulkhead behind front seat: 251 863 170

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garyd
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Re: Syncro engine swap - DJ to AGG

Post by garyd »

Patrick,
one thought for you before you fit the engine into your van. Consider replacing the studs and nuts both sides of the exhaust manifold if you haven't already done so.

My engine is currently out after 5 years of use and I wanted to seperate the pipe from the manifold. However, the nuts were badly corroded and eroded and had to be cut off. The studs were also in a poor way and thus needed drilling out & replacing. To do this meant removing the manifold but the nuts here were also badly eroded - it also meant removing the inlet manifold and engine mount arm to provide clearance. So, I am currently in the middle of replacing all the studs, nuts and gaskets. I didn't do this when fitting the engine so would recommend you take the opportunity while it is all accessible.

I suppose that the 50* angled mount probably allows much more water and road dirt to be thrown into this area than the Golf 15* mount (and bulkhead proximity) would. Especially when you through in a bit of off-roading - including the slurry of a wet Salisbury Plain!
Garyd

1990 Transporter syncro camper
2 litre AGG 'GTi' engine

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syncropatrick
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Re: Syncro engine swap - DJ to AGG

Post by syncropatrick »

garyd wrote:Patrick,
one thought for you before you fit the engine into your van. Consider replacing the studs and nuts both sides of the exhaust manifold if you haven't already done so.
Good idea. Mine look pretty bad now.
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tforturton
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Re: Syncro engine swap - DJ to AGG

Post by tforturton »

Any progress on this, Patrick?
1990 2.1 DJ Syncro Caravelle/Westfalia conversion RHD

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syncropatrick
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Re: Syncro engine swap - DJ to AGG

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tforturton wrote:Any progress on this, Patrick?
Nah! I could say SWMBO has given me lots of chores, but in reality I've been avoiding it. It'll happen when I feel like it.
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Re: Syncro engine swap - DJ to AGG

Post by silverbullet »

Being "in the right mood" is defo the way to go.
Motivated = light work.
I came home from work today and it was still light! It all helps.
85 syncro Caravelle twin slider Oettinger T3200E-6
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Re: Syncro engine swap - DJ to AGG

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Wanted: offside part of full-height walk-through bulkhead behind front seat: 251 863 170

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syncropatrick
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Re: Syncro engine swap - DJ to AGG

Post by syncropatrick »

Nearly a year later, I've picked up this project again.

SORTED
Need the 4 bolts that hold the 'Y' shaped JX engine mount to the block.
I've taken the AGG mount off, and 2 of the bolts are too long. I could cut them down, but don't fancy graunching the block threads with crappy thread bolt cuts.
http://forum.club8090.co.uk/viewtopic.php?f=19&t=158005
SORTED
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Re: Syncro engine swap - DJ to AGG

Post by silverbullet »

Steady on there old chap!
85 syncro Caravelle twin slider Oettinger T3200E-6
90 SA Microbus supercharged wbx/UN1 project

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syncropatrick
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Re: Syncro engine swap - DJ to AGG

Post by syncropatrick »

syncropatrick wrote:
garyd wrote:Patrick,
one thought for you before you fit the engine into your van. Consider replacing the studs and nuts both sides of the exhaust manifold if you haven't already done so.
Good idea. Mine look pretty bad now.
I'm glad I took the time to do this. A week of Plus Gas application first. Of the 14 studs, 3 snapped off (luckily above the surface) and I had to use a blowtorch, a candle and hammer to get them moving. All 14 needed the magic Irwin bolt gripper thingies to wind them out. I wouldn't have liked to have done that insitu.
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syncropatrick
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Re: Syncro engine swap - DJ to AGG

Post by syncropatrick »

syncropatrick wrote:
syncropatrick wrote:
garyd wrote:Patrick,
one thought for you before you fit the engine into your van. Consider replacing the studs and nuts both sides of the exhaust manifold if you haven't already done so.
Good idea. Mine look pretty bad now.
I'm glad I took the time to do this. A week of Plus Gas application first. Of the 14 studs, 3 snapped off (luckily above the surface) and I had to use a blowtorch, a candle and hammer to get them moving. All 14 needed the magic Irwin bolt gripper thingies to wind them out. I wouldn't have liked to have done that insitu.

And then one of the spark plugs goes wrong; the ceramic part with the nut parts from the thread inside the case. How to get that out?
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Re: Syncro engine swap - DJ to AGG

Post by Aidan »

syncropatrick wrote: And then one of the spark plugs goes wrong; the ceramic part with the nut parts from the thread inside the case. How to get that out?

plus gas patience plus gas patience heat and then "idiot" a suitable size torx bit into the middle of the remains and more heat then hopefully with a big bar and a decent 6 sided socket you will be able to unwind it, failing that I think it's head off job - you will have to vacuum out any debris that goes in the cylinder if you do get it out without taking the head off

I tried this once on the engine that now is in The Hulleys' bus, I failed and snapped the torx bit leaving a nasty spike sticking out that I couldn't get any further tool on - the engine went to Elite who probably just swapped the head

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Re: Syncro engine swap - DJ to AGG

Post by silverbullet »

That's a bugger. I would say that the safest way is to find a local "thread doctor" to come and drill it out. A good man will get that out cleanly and without the need for a helicoil (not the end of the world if it does need one). Spark plugs are far less challenging than seized glow plugs or injectors, because the steel is quite soft.
85 syncro Caravelle twin slider Oettinger T3200E-6
90 SA Microbus supercharged wbx/UN1 project

http://www.025motorsport.com

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syncropatrick
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Re: Syncro engine swap - DJ to AGG

Post by syncropatrick »

Result! A second week of PlusGas and use of a large screw extractor and a breaker bar matched with an Imperial socket, got it out!
Wanted: offside part of full-height walk-through bulkhead behind front seat: 251 863 170

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syncropatrick
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Re: Syncro engine swap - DJ to AGG

Post by syncropatrick »

Wanted - Syncro JX dipstick and dipstick tube. Posted to North Somerset.
http://forum.club8090.co.uk/viewtopic.php?f=19&t=158271
NOW SORTED.
Last edited by syncropatrick on 11 Mar 2017, 17:39, edited 1 time in total.
Wanted: offside part of full-height walk-through bulkhead behind front seat: 251 863 170

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