Big Daves 1.7ky-1Y Motor Conversion Thread!

[covdubber]

How do all i have a pretty cool vw crew-cab with a OK 1.7ky motor Which runs well if the oil is topped up to the brim of the max mark on the dipstick & it'll go anywhere but its using the oil pretty quick!!! so i thought bugger it!!! i sold my car & i've been out this morning & bought a VW 1.9D 1Y engine from a breakers local to me! & i'm hoping to swap that into my crew-cab before the weather go's completely breasticles-up!

the chap that runs the place was pretty pleasent (are'nt they all when you have £££ to spend!!!) he had a 1y motor in the in one of the storaage sheds where all the engines/box's are kept, he says they run all the motors they keep, they had a pile of engines to weight in outside & the apparently good runners indoors so.....i've took my chance! its set me back £240 the only thing i dont have is the power steering pump & gearbox which i dont need anyway!

so here it is in its glory!

i could'nt help myself this afternoon so i've took off the intake & exhaust manifolds off the 1y as they are'nt needed! allthough apparently the 1y intake manifold may fit in the crewcabs engine bay??? can anyone confrm that! whether i'll use it or not i'm unsure!

i believe this wire on the 1y alternator is the charging wire that hooks up to the dash warning light wire in 1.7 crewy


these are the 1y diesel pump wires, i'm unsure yet what hooks up where?


the red & white wires here i believe are the glowplug wires, i'll need help with the wiring part!


Now i have never messed around with a diesel before so its a learning process so stay with the "very simple" explainations :OP

so far i have turned the motor by hand with a long bar in the garage & lined up the timing marks, my plan is to change the glowplugs, timing belt, alternator belt, oil filter & possibly if i feel brave check & re-set the diesel pump timing! i have the orange JK 1.7 diesel manual, bentley manual, & i hope & pray i can do this conversion fairly quickly!

i'll need advice from those that have been there & got the T-shirt! pete abbot has been a legend by PM so far & i cant thank the guy enough for valuable info! which is in his thread called "petes progress"

my 1st port of call will be to GSF on monday to order parts such as the timing belt, glowplugs, alternator belts both 1y & 1.7 as i dont know what route i'm going regaurding belts/alternator/water pump yet! i want the easyist solution so i can have her running asap!

under the rocker cover

[covdubber]

i do have a question, how do i lock up the engine from turning so i can take the 1y clutch/flywheels off? i'd like to do it asap & also

i understand i need to use a spigot bearing apparently NOW is that the roller bearing that go's into the end of the crank on the flywheel end? do i ask for the normal t25 diesel spigot bearing when i go to gsf?

also what other things should i do to or with the 1y motor before i take my 1.7ky out of my crew-cab? what should i check & change as preventative maintainance?

also clutch, is the t25 1.6 turbo diesel clutch a stronger unit than the 1.7 one or are they the same? i believe its 215mm clutch plate

all advice/help is really appreciated!

[covdubber]

Right got the old 1y clutch off

kept the little metal gasket/shim & bolts

the back of the 1y cylinder head where the temp senser is (i think this is the water temp senser anyway? also is the plastic
inlet/outlet pipe on the back of the cylinder head on the 1.7ky motor, i really have'nt noticed!!! :O\ i'll have a look over the 1.7 tomorrow


is this whats called a vacuum pump? do i need it whats it for etc etc there seems to be wires on the top that have been cut?


some pics of the 1y diesel pump & wiring i need to give the wires a clean to see what colours they are clearly!




i can bolt things together in the wright place & right torque values & i can do bodywork & swap like for like motors but this is a mild stretch for me

i'm gonna pick up the vw timing tools to change the timing belt! should i change the tensioner for a new one???
i also would like to change the glow plugs for new ones but how the blummin-heck do you remove them behind the pump???

which is the inlet fuel pipe which is the outlet? i'll mark them up then in readiness!
[img]http://i428.photobucket.com/albums/qq8/ ... age013.jpg[/i

i think i'm gonna take the route of the good man mr pete abbott on here & use my 1.7 water pump, bottom pulley & alternator + v-belt! for keeping the wiring as simple as possible, i only have to worry about wiring the pump in then i believe???

[ringo]

Hello mate,

For the sake of £50 I would also replace the oil pump if your 1.7 has done a fair few miles.

The 1y inlet is good apparently, but the 1.7 inlet and air box looks good and will save some pennies. I used mine and it was fine.

To lock the crank I take the sump off and jam a bit of soft wood in between crank and the engine casing.

Definitely change the tensioner.

A normal diesel t25 spigot bearing is what you need.

The glow plugs are fiddly - I use the copper bus wire attached to the glow plugs loosely to ensure o can get the plugs back in.

Good luck!

Ringo

[ringo]

Oh, the inlet is normally the banjo next to the accelerator lever.

You will soon find out if you get it wrong!

[covdubber]

oh, oh what d'ya mean oh ringo?! :OO ) mine seem to be push on rubber hose fittings then i presume a a jubilee clip to make all tight! i'll have to compare the fuel pipe fittings to whats on my 1.7 tomorrow

you have reminded me something ringo!!!

what have other folk done to hook up the throttle cable & do any of you that have converted use the cold-start cable???? personally i've never used thecold start cable on the 1.7 & its not needed it as i let my motor warm up for a few minutes but on the 1y i dont know

[covdubber]

oh yeah & how do i lock up the motor to undo the crank pulley bolt! i have the biggest bar going to undo it if its tight!

[jamesc76]

looking good, but get a better camera thos pics are well hard to see!

[covdubber]

my only camera is on my 10 year old nokia mobile phone :OD its the best i can do at the moment! my picture taking skillz are'nt that great either LOL

more progress late this afternoon, i've took off the 1y alternator & some various brackets!

tomorrow i'm making a coupe of bracket type things which will bolt to the block, & the end of the crankhaft at the flywheel end, so it'll lock all in position so i can loosen the crank pulley main bolt!
i want to take the pulley off & remove the plasitc timing belt lower guard! which in turn i'll remove the 1y waterpump!

from there i'm then in a position that i'm ready to fit new compents such as timing belt, glow plugs, oil filter,

now one of my questions reguarding the 1.7-1.91y conversion

can i fit the 1.7 waterpump & crank pulley so i can also retain & use my 1.7ky alternator??? as this will serve ywo purposes, 1sdt is that it'll look more original-ish! & also i can just hook up my battery & charging system wiring as it is at present!

if thats possible???? i then only have to concentrate on sorting the wiring for the glowplugs & diesel pump
please advise where you can

oh & is there anywhere or anyone that has a link or diagram that shows how to change the 1y timing belt?
oh yeah before i head ot my bed-which piston is classed as No1??? is it the one closest the flywheel or the water pump???
cheers all from Dave

[covdubber]

A little more done this morning so far...........
got the 1y crank pulley off by removing the 4 allen headed bolts as per pete abbots advice! top chap! the lower plastic guard is off also!

i lined up all the marks & diesel pump & put a 6mm bolt in the diesel pump to lock it all in position before taking the botom pulley off


the cam pulley lined up


i cant figure out how to get the bloody water pump off? anyone help me, i've removed the 4 big bolts in the pic below


the pump also has bolts around its perimeter behind the water pump pulley, the water pump pulley is the one with the 3 allen headed bolts, you may see them in the pic below the ones i mean


i'll take better pics of the wiring on the 1y diesel pump & ask whats what in a bit, ie what wires i hook up to my 1.7ky wires to make the 1y run!!! hopefully!
i'll make a start & see if i can loosen & remove the 1y glow plugs, 12mm spanner i think & a pair of long nose pliers to grip them between un-screwing them! i hope there is enough room behind the diesel pump to remove them & replace with new ones
i hope i dont have to remove the 1y diesel pump to change them!
what tools do i need to change/lock/tension the cambelt?

[covdubber]

A little more done today, got the water pump off! what weird but fantastic bolts hold it in place!


i did notice my engine does'nt seem to have a blanking plate next to the oil filter housing so i'll have to pick one up, it looks the same size as the fuel pump blanking plate you'd fit on an Aircooled motor!
need some advice on what does actually fit here please folks

heres the best bit, i needed to lock the camshaft in position! obviously after bringing piston no1 to TDC so i can change the cambelt! anyhoo i could'nt be bothered waiting until tomorrow to get the £££ tools so to to lock the camshaft in position i found an old door hinge which was the same width as the slot in the end of the camshaft i used a welding clamp to hold/clock it in position, check this out


so here we are, i loosened the cambelt tensioner & slid the belt off!


so the next job is the glow plugs HTF i'm getting them out i dont know yet, i'm gonna pick up a vw diesel injector socket tomorrow to take the injectors out & see if that gives me some room to get to the glowplugs! if it dont then the diesel pump will have to come off
anyone got a guide or link to getting the 1y diesel pump off??? i'll have another bash at the glowys this afternoon after my yummy roast beef sunday lunch! ya never nknow the red meat may help me think of somthing!
let me know ya thoughts folks!

[gaz f]

Watching this with interest as I have a 1Y sitting in my garage and will be fitting it to my van soon!

Keep up the good work.

[covdubber]

Right a little more done this afternoon phhheeeewww i'm a bit shattard all this thinking

This is the diesel pump on my 1y engine, i dont know myself if its a lucas or bosch??? let me know please folks here it is:


these are the wires on my pump, this is on the bottom of the pump & the colours of wires coming from it



this is in the centre/sort of on top of the pump between the fuel pipes, it has a black wire coming from it


this is right in the centre of the pump between the fuel pipes, one wire is yellow the other is green & white i think


some more wires the black go's to what i think is the cold start cable/lever, do i swap this for my cable operated diesel choke (bowdan cable)


this is a 4wire connector which i believe may be for the coolent temp/level indicator but i'm not sure, i think its differant on the 1.7ky


Most of the wires terminate into this connector, do i cut this off???

[covdubber]

the red & white wires on the connector in the pic above go to the glow plugs, do i just joint these to the 1.7ky glowplug wiring when i swap the motors over????

& the oil pressure/temp senders & wiring is basicly the same is'nt it? same with the coolent temprature sender & coolent level indicator on the expansion tank???

i have no idea what you do with the vacuum pump?????????

i'm new to diesels ya know!

i'm picking up the parts i need for the 1y tomorrow afternoon so i shall fit some parts maybe tomorrow eve & do pics & basic descriptions as i go as i'm new to this sort of caper! i've swapped like for like motors but not done motors that differ!!!

its been fairly simple stuff so far so i hope it stays that way, the only thing i'm a little worried about doing is re-fitting the timing belt & re-setting the diesel pump timing so if anyone can help with advice or give me a hand please do!!! apparently it only take less than 20mins if you know what ya doing!

[colinthefox]

I'll try to help with the vacuum pump.

Vacuum is needed to operate the servo for the brakes. On a petrol motor there is enough suck at the inlet manifold to do the job. With diesels there is virtually no vacuum created by the inlet, so you need a vacuum pump. The flexible hose that goes to the brake servo connects to the non return valve which sticks out of the top of the pump....er. um......which you don't have cos it's been broken off. (They are often broken in removing the hose) So your choices are:-

1. Get a new vacuum pump.
2. Weld a 12mm tube spigot on to the pump top plate and fit a generic non return valve, and connect the servo to that. I was too tight to buy a new pump so did that and it works a treat.
3, Get a new pump top plate from a scrappie.

The vacuum pump also turns the oil pump, so don't try to run your engine without it!