Big Daves 1.7ky-1Y Motor Conversion Thread!

[covdubber]

also i picked up what "i think" is the right diesel fuel filter i should be using, i'll check with marcus "MERCDOCTOR" & als o two new oil pressure senders


just gotta get a couple of new glow plug relays as mine has possibly blown!

[peteabbott]

Yes Dave I used the original 1.7 dipstick and had to make the adjustments, 8000miles and no probs.
That filter has got me baffled, what do you do with the return or "spill back" ?
Any comments on this anyone ?
Good pictures by the way, you must have found your lead then !

[covdubber]

Nice one pete! i'll re-check my oil level tomorrow & see if i can "adjust"the dipstick to suit!

no'p still the old phone pete :OP i've used a bit of the old swarfega on it! lol

as regaurds the filter above the return line it'll just go from the diesel outlet pipe go's to the tank!

gonna get a little more done on the 1y motor tomorrow!

[covdubber]

Well i went to vanfest on the satarday to pick up parts & to be honest compared to last year the traders section was crap!
but aside from that i got myself a towbar & some bits n bobs

as for the 1y conversion i have my new glow-plug relay & temp senders & various items so tomorrow despite whatever crappy weather it is i'll be working on my motor!

hope to get it up & running this week hopefully this wedsday maybe!

i'll be giving mercdoctor a shout again for sure!

[weldore]

bliddy wednesday is the new tommorow..it never comes
get the thing done

[covdubber]

Right fitted what needed to be fitted today such as the fuel filter, glow plug relay, sorted the fuel lines but.....................

i'm not getting the glow plug light on the dash & the glow plugs are'nt heating, the glowys are new! as is the relay!

i'm seeing voltage at the glow plug relay connection in the engine bay!

any idea's?

[weldore]

have you blown the fuseable link in the black box of wire hell ???

[peteabbott]

I actually had a mate look in the black box of wires and he hasnt been seen since ! Fuseable link sounds a good place to start, When you say you have a voltage out of the relay does it "time out ?"

must admit my dash glow light hasn,t worked for months....switch on, count one banana, two banana, three banana and twist the key never fails. If I can find my mate in the black box of wires I will get him
to fix it

[covdubber]

i'm getting no feed to the glow plugs at all, i dont get it!

[weldore]

take a pic of the inside of the black box of misery for us(a close up one)

[covdubber]

NO PIC NEEDED FOLKS! things are moving forwards woohoo!

foud the problom today! the main problom was the feckin main earthstrap from the gearbox to the body was snapped!!!!

i jammed the broken bits of scraggy wiress back together just to test my theory! turned on the ignition & all the lights come on as the does the glowplug light!!! it go's off after a number of seconds then the motor fires up a treat! Woohoo! what a sence of relief!

so i gotta go pick up a earth strap in the morning so thats that problom SORTED! i must admit i put my fist to the air & shouted ""feck" yeah" when i figure the problom!

i let the engine run for a good 10-12 minutes so the water i added has circulated through the system & the oil, i have no fuel or water leaks so far but...........

i have oil pissing out my dipstick hole! i tried to use a pice of rubber tubing to locate the 1.7 dipstick tube but it has'nt worked! so i'm unsure what to do, i'll have to either use the 1y dipstick HAS ANYONE ELSE DONE THAT!!!! or get some plastic tubing to locate the 1.7 dipstick tune better & i'll either use chemical metal or araldite to seal that bugger in so it dont leak! bit of a fiddly pain in the a*** to sort but i'll sort somat! please advise what you chaps have done

the other problom is the engine is smoking a fair bit & when you rev the engine it stutters a bit so i think i've either got the timing belt a tooth out or the pump timing is off!
marcus MERCDOCTOR on here is gonna come give me a hand with that so hopefully that'll be that issue sorted too!

i have to als o fit the BRICKWERKS 1y conversion throttle levers tomorrow

so although i have'nt got her up & running on the day planned, with a bit of luck & some good knwledgable help from MERCDOCTOR she should hit the road towards the end of the weekend! or early next week!

also what has been pointed out by by the earth strap snapping is that the old 1.7 was actually OK & did'nt have oil pressure probloms as i thought, the oil pressure light was flashing as were all the lights due to the fraying/broken earth strap vibrating!

So in a sence swapping to my 1.9 1y motor has been a pointless excercise but on the flipside i have now got a more modern motor with more torque & the original 1.7 as backup!

more updates tom come & all advise is appreciated! & now my stress level has gone down i'll get a ream of pics & a video uploaded! keep ya eyes peeled folks!!!!!

[peteabbott]

[covdubber]

little update, got myself two new earth straps today & fitted one & all th electrics work a treat now! glow plugs etc etc etc, alternator is charging as it should be & all the MOT-able electrics work as they should!

i have also been playing with the 1.7 dipstick, i have trimmed the plastic piece th dipstick fits into in the dipstick tube, so now with 4.5 ltrs of oil & a full oil filter the dipstick now reads correct! as a rought guess-timate i think i've trimmed 12-14mm of the dipstick tube!
this leves the problom that the sipstick now slips out of the tube from engine vibrations when its running! i solved this by hooking a carburetter return spring onto the dipstick & to a hole/loop in the block! i'll take a pic, the only downside is i have to whip the spring off to take the dipstick out to check the oil level but thats no great shakes!

NOW for the more serious problom of the oil pissing out of the dipstick tube hole!

now the yellow plastic bit i cut off the top dipstick tube is the right size for the hole in the block 10mm outer diameter & 8mm inner diameter!
the hole for the dipstick tube in the 1.9 1y block is 10mm & the 1.7ky dipstick tube is 8mm so.........i've cut a piece about 10-12mm yellow plastic that i took from the top of the 1.7ky dipstick tube & slid it up to the shoulder on the bottom end of the 1.7ky dipstick tube are you still following/understanding what i've done-if not i'll have a pic to come tomorrow eve!

so the plan tomorrow is to use araldite or chemical metal to glue the 1.7ky dipstick tube with the yellow plastic sleave into the 1.9 1y block, i'm gonna use loads of the araldite/chemiacal metal so the hole is completely sealed & "hopefully" leak free!

having some probs fitting the brickwerks 1y throttle levers but should have tha nailed tomorrow!

i have worked out i need to add about 300mls of oil to my engine then i'll run the engine again & bleed the air out of the cooling system a bit better than i have

Need to check over the timing belt/timing marks & the diesel pump timing & once that issie is sorted she'll be out being test driven! so other than the pump timing which i think i'll need help with from marcus MERDOCTOR i should have it in as near as damit to driving down the street!

i'm getting there!

[weldore]

aye..you should be done for wednesday

[HarryMann]

apparently the 1y intake manifold may fit in the crewcabs engine bay???

Going back to page 1... (as a short diversion )

It fits but usually interferes with the n/s chassis. It is supposed to be good, and designed for the 1Y of course, but some 'clearancing' 'may' be required. Its the No. 3 & 4 pipes that touch, at the front, they can have at least any casting marks removed to help, even a bit of their thickness.

==============https://club8090.co.uk/forum/posting.php ... &p=7537762#

Re: Bad running. If you've loosened any of the injection pipes, removed an injector even (yes), go back and check those steps mentally. New heat shield(s) in correctly? Pipes dead straight and nipped up nicely (when idling, check for even the veeery slightest leak at any of inj pipe unions, ditto when revved)

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I'd suggest that you 'de-rate' your presumption that jubilee clips are always the dogs. Especially some £1 shopy looking ones I've spotted in some photos... At small diameters, they're often not the right thing, also, the original VW cooling hose clips are not rubbish, they provide an even 360 degree clamp, at the right value, on mine, after being removed several times and ageing over 20 years - just get a tool to remove and fit them.

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By the time you read this you should be finished, no such thing as a 5 minute job, eh? but well done, 99% there