Big Daves 1.7ky-1Y Motor Conversion Thread!

[weldore]

you could always try drifting the one out of your 1.7

[covdubber]

Right a little more done!
i've gotta hoax out the cable for my old phone so i'll pop up pics after my dinner when i have more patiance with the computer

i got the New cambelt & Tensioner on, had to buy a vw tensioning tool to be sure i tensioned the belt right, £8 aint much to gripe about for peace of mind!
rotated the engine 6 times & it seems to rotate with nothing locking up so i think i have fitted the cambelt ok

also fitted the spigot/piolet bearing into the end of the crank a per aidans advice, i got it in 1.6mm below the surface nothing got crushed, all the bearings in it rotate as they should & i have slipped some grease on it!

also fittedthe crankcase breather pipe

having trouble on seeing how to change the glowplugs without removing the diesel pump????????? anyone got any ideas?

i have some questions to ask when i pop the pics up in a bit

[covdubber]

here we go, new belt on & lined up + tensioner tensioned & engine rotated 6 times & nothing was binding or knocking etc etc





spigot/piolet bearing in


engine crankcase breather fitted which fills the hole in the block-cheers for the diagram weldore!



now there is this coolent pipe on the head is it the same fitting on the 1.7????


oh yeah is this the only wire i have to connect to get the 1y running???? i'm super unsure on this bit???


also there is this coolent pipe, is this one to be swapped with the 1.7 item?


cheers all

[weldore]

i swapped both coolant shrouds because there was the sensors on my old ones.
to keep the wiring the same
the fittings were the same

on my 1y the pump was exactly the same as the old 1.6 wireing wise...i didnt have any box to break off.thats always made me think it must have been a very early engine or the3 pump was not the right one

[weldore]

also i got my dipstick tube from the old engine to fit in the 1y by making a small bracket that bolts onto the back of the alternater.it might be something to think about before you put the sump on(if you havnt already)

[covdubber]

cool, nice one weldore! i can take these off tonight in advance then LOL

which of the fuel pump banjo's is the fuel in & fuel out? its says in my JK 1.7 book the outel is marked out but i dont think it is on the 1y?

do i leave the coldstart thingy-majig hooked up or do i use my manul 1.7ky cable?

i'm leaning towards using as much of the 1.7 stuff just so its easier to plumb in all the coolent hoses & wire it all up!

keep it as OE as possible,

[covdubber]

i gotta take the 1.7ky out yet! LOL i'm living in hope the weather drys up just a little bit!!!

so more than likely i'll be popping up more questions once i have the 1.7ky out!
i'm trying to prep the 1y as far as i can so it'll be a case of "hopefully" swapping the 1.7ky bits i need over with new gaskets & a clutch if needed then take some pics, check with you folk that have done the swap as a bit of re-assurance that i have all the bits on where they should be etc etc & get the bugger in, STARTED UP! hopefully in a nice running manner & post a video or two!

livin the dream hey chaps n chics livin the dream

[weldore]

looking at your pic the fuel return to the tank will be the long pipe off the banjo and the fuel in from the injectors will be the other side of it and proberbly be coupled up to them.youll proberbly have to turn it a bit to get the return pipe on
i think i altered the bleed off pipes so that number one injector was the return to the pump on mine...the throttle lever mech fouls it a bit but its been ok so far

[covdubber]

gonna label stuff up & get the 1.7 out 7 1y in in the next few days folks!

never took a diesel out before just Aircooled :/ arrrhhh

pics of the escapades to come!

any advice people?????????

[covdubber]

holy crap what a nightmare changing the glowplugs!!!!! specially the ones behind the diesel pump! the way i gained "just" enough access was to take all the diesel injectors out!

it looked like the two easy to change ones on my 1y motor had been done before but the ones behind the pump had not as the heater elements were shorter than the other two! the two that had been changed were a nats penis shorter than the new ones!

they are done now though so it should start nicely! i hope

i splashed out today to on a new sump gasket & a new clutch setup, i though it prudent to put a new one in to be honest so aslong as the replacement 1y runs ok it should hopefully run well for a while!

i also took the sump off & removed the windage tray & 1y oil pump in readyness for fitting the 1.7 ky parts

weather permitting i'm gonna start labeling bits on the 1.7ky & removing components to take the 1.7 out tomorrow afternoon!

i gotta tighten a few nuts on the 1y & sort out the non-return valve for the brake servo but i think i'm ready to do the swap!

[gaz f]

Good luck! Keep us posted....

and hurry up will you, I've decided not to start doing mine till you've finished.

[peteabbott]

Are you on your second tub of swarfega yet ? Weldore Dave had some left over I think

[covdubber]

gaz f my posts are coming thick 'n' fast over the next few days weatyher permitting!

Anyhoo!

the 1.7 KY wheeeeeeezing DIESEL is out folks!!!!!



it all came out pretty easy to be honest!

one bit that is a bit of a "bar-steward" is my diesel engine mounts are absoltely fooked! the near-side one was'nt even attached at all! the rubber had de-bonded from the metal part the bolt go's through, other than that it came out a breeze

took myself & my father of 63 just less than 2 hours!!!!!

all i used to take the motot out was my 2 ton jack & an axel stand underr the gearbox-job done
those OE vw rubber hose clamps are a load of toss, i'm swapping them to jubille clips

my clutch slave cylinder is leaking so i'll orrder a new one & new engine mount rubbers tomorow, i also need to go to a breakers for some new connectors for the sensers as the ones on my 1.7ky are broken they are missing the wire spring type things so they ratle when the motor is running so things light that will make dash lights flash!



engine back in the garage for me to strip & swap parts tomorrow, i'm going to blast at it & get as much done as possible!!!
the two motors on the garage floor ready to swap bits n bobs!


can i use the 1.7ky vacuum pump on my 1y?

the new aim is to get the motor in & running HOPEFULLY WELL IF ITS A GOOD ENGINE! & go down to VANFEST in it & see if i can get it in the hall where all the engine conversions are!

i know it is'nt the most radical engine conversion but for others to see & come n have a natter about what i've done & see it in the flesh may help a few folk! & as i'm a bit of a novice myself at this sort of thing!

keep ya posted tomorrow & no doubt with questions on bits i'm iffy about

[weldore]

my 1.6 vacuum plate didnt fit on the 1y thats why i took the valve out...theres a good tip for suspending the gear box and thats to use a length of 2x2 between the bit of the rear arms where the cv's go through..but you seem to have done it with that axle stand(dont let it drop off!).
and yes i did have a bit of swarfega left from my 5ltr tin pete..only a bit mind

[covdubber]

haha i love the smell of swafega! i like to mix it with suger to give it a grit to get into the nooks n crannys of your hands! theres a tip for for folk working on there own motors! also apparently a bit of sugar & olive oil is good, i dont lke the greasy feeling though

i'll see if i can tap the bit i need out of the vacuum pump, see how i go as

i am a bit ham-"interfered with" even if i'm trying to be delicate! fckin women LOL

my old-man has been to B&Q & took advantage of the cheapo £20 pressure washer offer so i'm gonna get some degreaser so once the 1y motor is all built up with the 1.7 bits n bobs i'll give it a proper good clean-up! at least i'll be able to see any oil/water leaks etc

is the cold start strictly needed? i ask as this is my 3rd t25 diesel & i've never needed the coldstart choke thingy1
when its really cold ie frozen screens locks i've always just turn the ignition on & wated for the glow plug light to go out, turned the ignition off & back on & waited for the glow plug light to go out a 2nd time then started the van! it chuggs a bit but by the time i've cleaned the windows etc the engine runs smooth & off i toddle!

also one key thing! what grade of oil do i use on the diesel? i've always just used a 20/50 multigrade suitable for petrol & diesels? let me know what i should be using?

from what i've read on various posts on doing the 1y conversion i apparently have to move the section of wiring loom that sits behind the airbox up out of the way as the 1.9 1y motor is a bit taller! hope that makes sence?

anyone have any suggestions of things worth doing whilst the motor is out?

oh i did have one breakage! cause my my old-man but its somat that usually happens, he broke off one exhaust stud where the exhaust manifold tube bolts on "bar-steward" LOL

he can fix that too! :O)

i plan to fit the 1.7 water pump & alternator & run the older style V-belt, for me the reason why is, its gonna wire up the same! i dont mind adjustng my belt tension every 100o miles, & its should make the installation go a little quicker i hope!

the best way so far to view the conversion as i see it is that the cylinder head & block & diesel pump is all 1.9 1y the rest is as it was on the 1.7ky

anyhoo i'll update tomorrow with more ramblings!