replacing 2.1 wasser boxer with 1.9 td

[bigdubber]

hi there
what do i need to convert my syncro crew cab from 2.1 to a 1.9 td.
already have low mileage one owner from new full service history 1.9 td "aaz"
what do i need for the conversion

[lloydy]

speak to syncronutzs. From what i've heard you basically need a diesel van to take lots and lots of parts off. mucho mucho money
Lloyd

[Russel]

You need ALL the syncro diesel parts.
Russel

[..lee..]

i`m doing the same only with a tdi. lots of head skratching ahead.

[Aidan]

[HarryMann]

There's a list of parts on Brickwerks' site...

The main ones are the sump, bellhousing, and engine mounting bars, rubber mounts and mount castings, and a Syncro TD fuel tank (for the starter motor relief)

The syncro TD sumps are few and far between. There are about 3 sump variants?
TD Syncro; TD 2WD;NA 2WD

You can re-engineer a TD 2WD sump at least by cutting an oil drain hole at the front, which I believe is the main difference (so can drain oil without removing engine underrun pan).

You also need engine bash-plate quite different than the petrol one.

You ideally need the electrical relay box (n/s rear of engine compartment) and the fuel lines and fuel filter mount, though can make up your own (& maybe improve on VWs)
You need a Diesel TD starter motor, a spigot shaft needle bearing and a TD clutch and JX flywheel

You have to decide what pulley alternator arrangement going to use, simple JX balancer and pulley or the AAZ one
You might need a few of the plugs that go into your water and oil temp senders (to save hassle), some cooling parts, hoses, water outlets/manifolds

You have to decide which exhaust and inlet manifold arrangement to use, AAZ or JX and whether JX (low) or AAZ high turbo position and fabricate an exhaust system and fit JX silencer & mounts (usually)

I've probably forgotten a few things, you might like a revcounter to replace your clock at least, if not a few other instruments

Oh, either the water/het exchanger off your 2.1 or a full-flow oil-cooler up front and hoses... quite importnat for longevity
===========

Alternately, you could mount your engine upright, some recommend that for a high turbo, good oil return, installation. That would mean fabricate engine mounts and an adapter plate. PC52 has a template or could maybe supply you with a plate... not sure if they are off the shelf anywhere.

Lacking any JX diesel parts, this might be the besty route actually... if you can acquite or fabricate yourself and don't want a quick bolt-in solution (which still won't be even with everything to hand)

So if engine height is not an issue then consider this route seriously. I certainly would today, the final result being better

[lloydy]

Hmmmm i've just picked up a diesel westy today [1.6na], that will be split for parts when i get my syncro

[syncropaddy]

A lot of that stuff is syncro specific as well so be careful!

You will also need the wiring loom for the engine and all the relays and someone to wire it up!

[Simon Baxter]

hi there
what do i need to convert my syncro crew cab from 2.1 to a 1.9 td.
already have low mileage one owner from new full service history 1.9 td "aaz"
what do i need for the conversion

What you really need is LPG, quicker, simpler, easier, cheaper.
I know lpg is a bit limp wristed but going from a 2.1l to a AAZ seems like an awful lot of work for something marginally better, if your going to the effort of putting a Diesel in then I would be putting a worthwhile Diesel in there.

[jed the spread]

what do i need for the conversion

Congratulations for your splendid decision

jed

[SyncroSwede]

hi there
what do i need to convert my syncro crew cab from 2.1 to a 1.9 td.
already have low mileage one owner from new full service history 1.9 td "aaz"
what do i need for the conversion

What you really need is LPG, quicker, simpler, easier, cheaper.
I know lpg is a bit limp wristed but going from a 2.1l to a AAZ seems like an awful lot of work for something marginally better, if your going to the effort of putting a Diesel in then I would be putting a worthwhile Diesel in there.

bigdubber, if SB says this ^^ given how much he hates the WBX then you know the conversion is going to be nightmare!

[jed the spread]

I have both, if an AAZ is 10 out of ten a 2.1 has got to be a three on sooooo many levels especially on a syncro, and thats a dj. Baxter has been drinking yorkshire moonshine, or mild.

jed

[syncrosimon]

Shouldnt that be 9 out of ten Jed as the WBX can do 9 out of 10 of the things a diesel can do, or is your wbx just a bad one?

Why on earth would you spend 5 grand on a diesel conversion.

Spend 5 grand on going somewhere interesting in your WBX is money better spent.

[Simon Baxter]

I have both, if an AAZ is 10 out of ten a 2.1 has got to be a three on sooooo many levels especially on a syncro, and thats a dj. Baxter has been drinking yorkshire moonshine, or mild.

jed

no, what I'm saying is that it's a pain in the ring swapping a petrol to a Diesel and do it convincingly.
taking a tank out is a ball ache, Diesel tanks aren't falling off trees, with the labour involved and the cost of all the syncro Diesel parts it won't be a cheap job.
just seems daft to do all that work and go from a 112hp engine thats already there to a 75hp engine that isn't.
If you are going to convert petrol to a Diesel then at least put a TDI in there that your going to feel the benefit from, AAZ's are great, when your JX blows up as they are a dead easy upgrade but going from 2.1 to AAZ just seems an expensive way to be really dissapointed.
At least with LPG you'll get some reasnable economy albeit with a unreliable dog toss engine and a loss of a load of internal space.
At least if it was TDI'd then he would even get away without changing the gearbox at first, some tall tyres would see him right for a while until he could afford a step up in gear ratios.

[jed the spread]

Shouldnt that be 9 out of ten Jed as the WBX can do 9 out of 10 of the things a diesel can do, or is your wbx just a bad one?

Why on earth would you spend 5 grand on a diesel conversion.

Spend 5 grand on going somewhere interesting in your WBX is money better spent.

Oh Simon tut tut tut I do like you and your quirky ways, in fact as you know respect your opinion and often ask for your advice but where the hell did you pluck 5k from?

Have you ever driven an AAZ?

The difference between the two off road is huge... especially through water

My DJ was fitted well, and was one of the last ones VW did new with about 40,000 miles on it now and Baxter fitted it before I owned it. It can"t do 9 out of the 10 things the AAZ can do even though the AAZ is in a much heavier vehicle. I can only keep my fingers crossed that one day we shall actually meet so i can show you. Bring your hat

jed