2.1 into 1.9 engine swap

Post by **Hacksawbob** » 19 Dec 2006, 14:08

Any thing to watch out for, any gotchas, extra parts etc etc

Post by **ermie571** » 19 Dec 2006, 14:25

Hi Bob,

when we did this we had to cut the front to back water pipes.(not sure if this would be the case for every 2.1/1.9 replacement)....not easy, and we managed to put a crack in one of them that has been a bit of a pain to rectify....think we have just about managed it now.

As for extra parts....think we had pretty much the complete engine to replace it with, incl exhaust. We didn't use the injectors, using the carb as it was gas converted; gasure said it was easier to run on carb.

done it in a day with headley's help - even got it running on gas!

Hope this helps

Emma

Post by **Hacksawbob** » 19 Dec 2006, 16:17

right you needed to shorten the coolant pipes? that run the length of the van? what was the issue with the existing, too long OK, but what were they fouling?

Post by **trundletruc** » 20 Dec 2006, 10:15

Why do you want to change to a 1.9? I am in the process of putting in a 2.1 from a 1.9.

TRUNDLETRUC

Post by **ermie571** » 20 Dec 2006, 11:15

hi again - just to be clear....I read it that the 1.9 was out, and the 2.1 was in.....that's what we did.

right, the pipes, in as much technical detail that I can muster...

the water pipes run into a black plastic housing....(thermostat housing?). In the original 1.9 set up, this housing was in front of the metal sheet that forms the rear of the engine bay.

When we put the 2.1 lump in, it was in a totally different position, requiring that the long metal pipes be cut.

Husband set-to with small hacksaw under van, and due to tiredness, smashing weather (ask Pete about Kentinsh weather!

), managed to put a hairline crack in one of the metal pipes. We didn't realise this until she was refilled with coolant.....

A rubber sheath has for the time being solved the problem. We have a set of plastic ones to go on.....but until we are sure they will fit, and we have got the nerve up to drop the tank, the repair will do!

If you want pictures shout...the van is a A reg, and I am assuming that the 1.9 that came out was the original engine. It was a 1990 2.1 that went in.

Hope some of this makes sense...

regards
Emma

Post by **Hacksawbob** » 20 Dec 2006, 12:59

yes trundle 21. going in 1.9 coming ou. Thanks Emma. I'll take a look. is it the thermostat (on the left) or the "tree" that the long pipes connect to (on the right hand side)?

Post by **ermie571** » 20 Dec 2006, 13:52

Bob,

Thinking about it, the thermostat has the electric wire plugged into it (coz the guage moved when we connected it), and since I did that bit (pat on back!

) I remember that it was on the left hand side, and was NOT the part that was moved

The part that we moved was a tall piece of plastic that all the pipes ran into - there is a rubber pipe that angles down to connect to the water pipe. It sounds like the "tree" you mention. This WAS the part that got moved.

When you planning on doing this? we can always have a look at ours and describe it better.

Good luck, and boy will you notice the difference.
We found that we had alot less oil on the floor......leaky push rods and damaged pushrod tubes was the reason for the change over!

Emma

Post by **Mocki** » 20 Dec 2006, 14:39

emma, the plastic pipe do fit, i changed to them with my van ( which is early water sys, they are just a bit tight to get the early rubber pipes on, BUT beware, diesel plastic pipes are shorter, you have to be sure they are from a wbx

and i didnt drop the petrol tank off either, its fiddly, but can be done, you just have to jack the van up higher to wiggle the pipes in and out without dropping the tank

Post by **ermie571** » 20 Dec 2006, 15:04

Mocki,

thanks for that.

By jacking the van up higher....is this so you have more room underneath to work?

we have laid the pipes under the van and offered them up as best we can, and they look alright. We were told they were off a wbx, but having had the warning we will make double sure!

Have heard tales that the diameter is slightly bigger....and as such the hold in the chassis that they pass through has to be enlarged....any truth in this?

thanks for letting me know

Emma

Post by **Mocki** » 20 Dec 2006, 15:11

it may depend on age of van, mine is 84, but w didnt enlarge anything,
and we only had to jack up higher to allow the room to manovre the pipes through the tank void......

iirc there are only two lengths of pipe, same as metal, and shorter, someone with ekta should be able to do a part no check for you.......

the hardest job was removing the old metal pipes, which looked thin and rotten, but were infact strong and only rusty on the surface...

Post by **Hacksawbob** » 20 Dec 2006, 19:23

Late water sys on mine. got a 2.1 lump to put in, if the fix to 1.9 head leak is to much bother. thinking of sending it to MSC up in Barrow for other work too as MOT is looming. What did you do about oil cooler? fit a 2.1 pump and hoses?

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