I'm an idiot.

[dieseldave]

1.6 diesle 1y caravelle E reg

Hello chaps,

I wonder if you can help me out. I've been scouring the wiki and the forums to try and find the info i need but not having much joy and not sure if I've got the full picture.

I've just bought myself a 1.9d 1y engine off of ebay (out of a seat) sounds genuine enough.

I now need to know how to go about dropping out the 1.6 and putting in the 1.9 (and doing it PROPERLY)

Is there a step by step how to guide written by anyone? I can find bits of info here and there but have a real worry that I'm going to miss something vital and balls the whole thing up.

The 1.6 is p*ssing oil out in all directions (several leaks in several places) is very low on power (I guess they all are) and produces more smoke than the red arrows...

so I figured the "simplest" thing is to bung another engine in and start again.

What are the key things I need to make sure I do?

So far I gather I need to change the oil pickup (althoughI have no idea what this is or how to do it!) and I think I'm probably going to have to fit a bearing to a shaft, can this be got from my 1.6 once I've pulled it out? or do I need to buy a new bearing (only the best for my bus!) if so what? and where/who from?

There's probably a sump thing to change as well...

Is it best to take the engine out the bottom of the van or hoik it out through the hole in the floor with a hoist?

should I also change the cluthch while I'm at it? is this a major job?

I've got a Petrol Haynes manual but have been unable to find a diesel verison.

Is there anywhere I can get hold of a diesel haynes manual or similar?

Where am I likely to go wrong?

I understand the dipstick will be incorrect for the car engine once it's keeled over in the van.

I apologise for wasting your time if the info is already available and you could point me to it I'd be very grateful.

cheers

Dave

(I'm called diesel dave due to be covered in it often not through any technical ability)

[Fritz]

Have a word with one of our Northern Munkies who goes by the name of The Grumpy Midget, he may be able to give you advice on how to complete this job.


Regards


Fritz,,,,,,,,,

[toomanytoys]

I am sure the alt engine forum has the info... But as Fritz says, worth having a word with a !Y "convert"..
But.. you are on the right track.. sump and oil pump/pickup, Manifolds is a possability..
Engine will not come out throught he top.. van up in the air and drop engine and box will be easiest..
Do a cam belt etc change before it goes in..

[HarryMann]

Simon's answered some good points, more here...

So far I gather I need to change the oil pickup (althoughI have no idea what this is or how to do it!) and I think I'm probably going to have to fit a bearing to a shaft, can this be got from my 1.6 once I've pulled it out? or do I need to buy a new bearing (only the best for my bus!) if so what? and where/who from?

Use a new spigot shaft bearing (pictures in Wiki)

There's probably a sump thing to change as well...

Old sump, new gasket (either simple JX style gasket (1.6TD) or the integrated gasket splash plate
New oil pump (best), fit your oil pickup to it (after thoroughly checking cleaning it)

Is it best to take the engine out the bottom of the van or hoik it out through the hole in the floor with a hoist?
Bottom, complete with box, ditto refittting

should I also change the cluthch while I'm at it? is this a major job?

Not a bad idea, use a JX clutch, check clutch operating arm for free movement and forks for any burrs

I've got a Petrol Haynes manual but have been unable to find a diesel verison.

A paper one would be easier to read

Is there anywhere I can get hold of a diesel haynes manual or similar?

Borrow a Bentley Manual

Where am I likely to go wrong?

Fitting the sump, be careful, check everything, clean all block blind threads and small set-screws, check for stripped threads and don't tighten long bell-housing through-bolts before sump is pulled up to block. Theres a recent thread on here about that, do some searches (using the Search facility)

I understand the dipstick will be incorrect for the car engine once it's keeled over in the van.

Yes, there's a Wiki topic on one way of shortening it. Recalibrate using a total of 4.5 litres of oil.

https://club8090.co.uk/wiki/Pa ... k_Oil_pump

https://club8090.co.uk/wiki/Parts_-_Part_Nos

https://club8090.co.uk/wiki/Di ... p/Oil_Pump

Ringo's links

PS. Good luck, if in doubt, ask

[peteabbott]

Just to add my twopenneth. When I did mine (hope I am not boring anyone) I put two pieces of 4X2 timber front to back across the engine hatch, sat two trolley jacks on these fully extended. Ratchet straps over the individual jacks and secured to the engine. Remove all bolts, pipes and mountings etc. Wriggle engine free (oops support gearbox first) then lower jacks till engine lands sweetly on the deck. Jack up van and pull engine out. The spiggot bearing goes into the end of the 1Y crankshaft with the small oil/dust seal outermost. Off the old engine you will need mountings, sump, oil pump (stange angle to reach the oil) manifolds and I changed the whole water pump but think you can get away with just changing one of the hose fittings. Beware of the thick sump gasket, use the thin one as not in every case but the extra thickness does not allow the bottom two bell housing bolts to line up. Dipstick.......last job, new oil filter 4.5 litres of oil thats the top mark on your stick, I cut the top bit off the tube until it read right. Engine back in, if you get it slung right with the two straps on the jacks you can lift one side or the other of the engine to get it at the right height and angle. I did mine by myself and found it safer working above the engine this way rather than perched on two jacks, that is if you havn,t got an engine hoist of course ! Next question you may ask......loads of wires on the 1Y pump ?? you only need the black one to operate the fuel solenoid. OK I will shut up now and hope this helps,
Come on boys add your bit, pull me to bits and we can put it all together and print our own engine swap manual.
Oh yes you will need Two tubs of swarfega Good luck next step from an idiot is a madman n thats me.

[peteabbott]

A few piccies, god I am a nerd.
https://club8090.co.uk/forum/viewtopic.php?f=12&t=49335" onclick="window.open(this.href);return false;

[weldore]

and....take your time

[oldiguana]

i did marn threw the top engine lid......went in a treat on me engine crane with everythin apart from the alternator...i think!!........................

[HarryMann]

Yes, can be done though the top engine hatch...

But if you are building the whole thing, clutch and all its not a bad idea to get the whole assembly sorted and 'unitised' and just slide it underneath... Certianly Syncro boys tend to do that fairly regular basis, just need to lift the whole truck back up quite high and low slung creeper helps to roll it under (or a trolley jack). 2 spare hands if not 4 helps, if they know what they're doing

[oldiguana]

totally agree owduck...i had gearbox already in situ,but bought myself a cheap engine stand,as i was doin it on me tod!!........big up the 1y crew!!!

[dieseldave]

Fellers!

Thanks for all the info. I've just this minute checkedout of brickwerks and have ordered:-

1 T3 Diesel spigot shaft bearing 410 0009 10
1 T3 Diesel oil pump 113 011 0003
1 1.9D/TD Sump gasket inc. baffle 447.340
1 T3 D/TD Cambelt CT513

I think that's right innit?

Was going to do the clutch as well but am pretty confident that the one already fitted has got a fair bit of life in it... and I reckon if I can drop the engine out once then doing it again in the future to put a clutch kit in won't be the end of the world.

I've also bought myself a very large tub of swarfiga...

The bloke I bought the engine off turned up at my long suffering mum and dads place (near bristol) yesterday having driven down from Newcastle to deliver it! "we set off at 2 in the morning like!"

Mental, I am enormously chuffed with that!

for changin the cambelt I mark all the pulleys with tipex so they stay in the same postion relative, pop the old belt off and put the new one on is that right?

in respect of the sump, the windage tray and integral gasket kit will fit between my old sump and the new block is that right? (once I've cleaned all the threads and done everthing as directed in the wiki)

I think I'm getting there (well theoreticaly so far...)

As you can see from the above list I've also bought a new oil pump from brickwerks which I fit to the old sump is that right?

As i understand it the stuff I saw about the windage tray said that the pump/pickup from gsf had to use the original VW one (interference with the webs?!?)

but the pump I've got from brickwerks needs no mods?

Have I got that right as well? or am I barking up the wrong tree? Is the pick-up the spindly stickey out bit of the pump?

Any more help and guidance gratefully received.

I'm already figuring out how to rig trolley jacks, ratchet straps and dunnage to drop the engine and box out. In the absence of a proper manual Safety aside are there anythings I should be aware of before droping it all out. I read somewhere about disconnecting the gear linkage so you don't bend it (that makes rather a lot of sense!) but is there owt else I should know?

Thanks for all your help.

dave

[dieseldave]

addendum


er... will I need to sort out a new exhaust manifold as well? or will the 1.6 one bolt straight on?

[peteabbott]

Sump baffle ? I read on here somewhere not to use the sump baffle .......... I didnt fit one ......... comments please fellas. I think the ports on a 1.7 are OK although a tad small but I think the 1.6 are even smaller. Brrrm brrmmm your nearly there

[oldiguana]

ar didna fit the baffle owduck...........n as for the timing belt,you need to be a lil' more exacting really,i made all my timing kit for mine,(pin for lockin the fuel pump,shimmed plate for lockin the cam,and a tool for lockin cam sprocket when tightening the bolt up)......its pretty difficult(impossible)without it to get it right....imho

[SplendiferousII]

Give me a call if you want to know anything. I amn only up the road in Gloucester if you need help.

07976 086 265

But your on the right path.