2.0L engine in original 1.6L van

[festivalgirl73]

Hi, Anyone had any problems with having a 2.0L engine put into what was an original 1.6L van? This is what has been done to the van I have bought and it appears that the clutch is extremely stiff as a result, I've been told its something to do with the fact tht the originl engine would have had a clutch cable and 2.0L would require hydraulic but mine has the 2.0L engine with the original cable, I'm not mechanical minded at all so its all a bit gobbledeegook to me, but I'm worried that this will cause me constant problems, the garage that looked at it today said they would not even touch it as they said it was a mish mash of engine parts and they didn't want to know! (Don't worry Kate not the garage you recommended, as he couldn't fit it in this morming in the end so it went round the corner instead for all the good it was!)
Anyone got any words of wisdom or encourgement cause I'm worrying myself to death here, the garage this morning made it sound like it was a liability to drive it!

[A KIRK]

Personally if ytou can cope with the heavy clutch just drive it and enjoy it.

I guess it also depends whether you have the 2l gearbox to match the 2l or whether ytou still have the 1.6 one, you could go down the road of installing the hydrulic system and replacing the gearbox if it still has the 1.6 gearbox.

It shouldn't make any difference to the running of the engine etc, as all the hydrulics do is make it easier to press the clutch, nothing dangerous about it. Its just the cheaper way of putting a 2l engine into a 1.6

[dugcati]

Personally if ytou can cope with the heavy clutch just drive it and enjoy it.

I guess it also depends whether you have the 2l gearbox to match the 2l or whether ytou still have the 1.6 one, you could go down the road of installing the hydrulic system and replacing the gearbox if it still has the 1.6 gearbox.

It shouldn't make any difference to the running of the engine etc, as all the hydrulics do is make it easier to press the clutch, nothing dangerous about it. Its just the cheaper way of putting a 2l engine into a 1.6

here here - well said that man...

[Therunner]

hmm, still sounds like something's rubbing though

be patient & see what Mark has to say

(or buy a Laurie engine,.. sorry couldn't resist the plug )

[richnewton]

Personally if ytou can cope with the heavy clutch just drive it and enjoy it.

I guess it also depends whether you have the 2l gearbox to match the 2l or whether ytou still have the 1.6 one, you could go down the road of installing the hydrulic system and replacing the gearbox if it still has the 1.6 gearbox.

It shouldn't make any difference to the running of the engine etc, as all the hydrulics do is make it easier to press the clutch, nothing dangerous about it. Its just the cheaper way of putting a 2l engine into a 1.6

this is exactly what i have done, fitted the 2 litre engine and box but still with the cable clutch. must be honest I haven't noticed that its particulary stiff. maybe check out the conduit is ok and the cable isn't snagging on it.

http://www.justkampers.com/shop/type_25 ... nduit.html

The cable itself is fairly easy replace.

[VWCamperfan]

The clutch shouldn't be as stiff as you make it sound. I'm quite sure the operation etc. of the clutch is ok or you would more than likely have had a problem by now.
Two things spring to mind which can make the clutch pedal stiff. The routing of the cable and lubrication.
Check the cable from pedal to clutch (where you can see it!) and make sure there are no sharp bends or kinks in the cable which can cause friction.
Now, idealy, if you can do it, the clutch cable should be taken out and oil dribbled down it until it comes out of the other end. Failing that, squirt a load of WD40 down the outer cable from the clutch end. Will be easier with the rear of van higher than the front. Do this with the little red straw that is supplied with the WD40 and try to block up the open end where you are spraying to stop any coming back out.
Hope this helps.

[bigherb]

As VWcamperfan says the clutch should not be that heavy and check the routing (bays had a cable operated clutch on the 2 ltr) it could also be the pressure plate spring has work hardend if was not a new clutch.

[VWCamperfan]

Ooh, should have said (doh!). Alongside the gearbox, there should be a 'dip' in the clutch cable. This is to allow for movement of the engine and gearbox when running. The dip looks like a shallow 'u' shape and should be dipped down about an inch and a half from straight. If too little then the clutch operation can be erratic when running. If too much then the clutch cable will be stiff and difficult to operate.
Tape measure time!

[phade]

The clutch shouldn't be as stiff as you make it sound. I'm quite sure the operation etc. of the clutch is ok or you would more than likely have had a problem by now.
Two things spring to mind which can make the clutch pedal stiff. The routing of the cable and lubrication.
Check the cable from pedal to clutch (where you can see it!) and make sure there are no sharp bends or kinks in the cable which can cause friction.
Now, idealy, if you can do it, the clutch cable should be taken out and oil dribbled down it until it comes out of the other end. Failing that, squirt a load of WD40 down the outer cable from the clutch end. Will be easier with the rear of van higher than the front. Do this with the little red straw that is supplied with the WD40 and try to block up the open end where you are spraying to stop any coming back out.
Hope this helps.

Using maintenance spray, PlusGas or spray grease is far better than WD40. WD40 dries out, where as the other stuff I've just mentioned does not.

[VWCamperfan]

Using maintenance spray, PlusGas or spray grease is far better than WD40. WD40 dries out, where as the other stuff I've just mentioned does not.

It won't run along the cable casing either!
WD40 does partly dry out but leaves behind the oily quantity of the spray, leaving the sprayed part... Still lubricated!

[festivalgirl73]

Well folks the clutch has been done £240 later! and thats feels much better, but the gears are still a problem, and apparently it has now been determined that it has not got a 2.0l gearbox to go with the 2.0l engine so this is causing all sorts of problems, the garage also said that the gearshift rods had been welded and in his opinion is was a right bodge job, the conduits broken apparently, don't really know what that means, but basically it looks like its going back in once we can source all the right bits and pieces, I'm not happy, I've been well and truly done over (by the people that sold me I, not the garage I mean), they saw me coming a mile off, only had the van a fortnight and not been able to drive it properly yet

'an excellent runner' 'a recon engine' 'new gearbox' (yeh, the wrong one!)etc etc I really should stop be so trusting, silly cow that I am