Converting 1.9 DG Petrol to ........

[discostu117]

I've had a good look on the wiki and forum but am still not sure what would be the best option to replace the 1.9 dg in my 86' T25.

I will be getting a mechanic to do the work so labour cost is a major factor. I am looking for the most cost effective and best mph option.

Can anyone advise what what would be the most economical, relatively easy to source engine requiring minimal tinkering?

Really appreciate any suggestions,

thanks,

Stu

[ninja.turtle007]

2.1 WBX. Anythings else will require a lot of parts and work.

[discostu117]

I was originally thinking of just getting a easy fit recon but when I looked into the cost and potential for It to clap out after the 12 month warranty put me off. I hoped there might be an alternate option costing similar money bit with improved economy over the 20mph I'm getting to reduce running costs.

[Plasticman]

well if the engine you have is running ok and your just sick of the ££££££ then get it gassed, fixed price end of problem
mm

[discostu117]

The engines pretty knackered. It burns oil at quite a high rate (no leaks or oil in the coolant though) so was thinking of replacing it before it fails the MOT on emissions.

Any other options?

[waltraud]

2.0 lts 8v Golf GTI AAG engine.

Diesel conversion engine bars, bellhousing, sumpt etc approx £350 all in for the parts you need.
GTI engine and loom , max £200
Parts incluidng fuel pump, possible cluth etc £200-
The bits i forgot
All in say £1000.
Much more reliable and less prone to being crap than a 1.9WBX, cheaper than a 'reconditioned unit' (read the samll print) from el cheapo Elite engines. 115BHP!!!

[discostu117]

Thanks, that's really helpful!

Do you know what MPG I could.hope to get with a GTI engine?

Given I'd be paying a mechanic does any one know a rough idea of how long taking out the old and installing the replacement could take?

Am I correct in thinking all the bits I'm addition to the engine would have to be source second hand or would some parts still ne available new?

I'm happy taking the time to source parts and you've given me a good idea of what I'd need. Is there a full list of all Tue required parts any where online?

Sorry for all the questions but I want to get all the facts before venturing further.

Really appreciate all your help.

Stu

[toomanytoys]

How much can you afford/think it might cost.prepared to invest??

Going from wbx to anything else requires either an adaprter plate (not ideal but ok if made properly) or a bellhousing
any 4cyl "I4" (inline from a golf/passat/audi etc) will require the T25 diesel bellhousing, mount, etc etc et... custom exhaust (unless Diesel stuff will work well enough)
Then if you go that route your man will need to be either quite hot on electrics to wire it up with original ecu etc... (= time = £££) or use a suitable carb system intsead...

If you can do a lot of the work yourself, then you can save a lot of cash on an engine conversion (as quite a few have done so), but for a reliable properly done engine conversion drive in drive out.. I cant see much change out of 2500 - 4500... depending on what and could easily be a bit more..

There is a lot of info in this forum, lots of it has been repeated lots of times.. but it does take a bit of time to find it..

Realistically.. MPG is never going to be great.. subaru conversions seem to return 30mpg if driven reasonably sensibly.. you'd prob see the same from a 2L "I4"
Diesels prob 35mpg ish (TD's as a non turbo isnt an option really.. )

One thing to bare in mind.. if you went 2.1 wbx (which can use all your existing DG ancilaries) and LPG it.. yes you will still spend the 2500 bu the LPG conversion will start paying for itself every fill.. the extra money spent on a scooby/TD etc, will buy a lot of LPG miles

[discostu117]

Thanks, I guess the reality is I am not very handy so will either end up spending a lot on labour or I do have a mate who can do quite a lot but I don't want to take advantage of his generosity and time too much.

I was originally budgeting up to £1,500 for a straight swap recon 1.9 DG.

Then after reading some posts I considered the other options where I might be able to end up with a more modern, reliable and fuel efficient engine.

If in reality the cost is likely double and the fuel economy won't increase greatly then my money would probably be better spent on a recon and then I can get it converted to LPG when I have the funds. Is this the case?

My only lasting worry about the recon route that is whilst you often get a 12 month warranty people seem to get a wide range of experiences on their quality even when buying from the same company.

Thanks for all your help so far and any other guidance you can give. I want to make the right choice for the long term as the rest of the van is really solid.

[waltraud]

If you get a DG recon I would get a Remtec, vege or if he's still working then ask that Italian? guy in London called Marco Mansi. but if anything on your engine needs replacing like exhaust and cooling system then it's going to be more ££££.

If you can't to it itself you might be lucky to get a semi-pro ( ie a scrote who enjoys it) to do an AAG for a grand if you literally had all the bits together. OR get u and your mate to take out the old engine, clean up, fit mounting bars and diesel bell housing. Get a Gti engine and assemble parts....then see if someone off here would drive to you to fit it up. There are many helpful posts on here re AAG conversion.

[discostu117]

Thanks,

My mate recently converted his own Diesel T25 (can't remember to which engine), has room on his drive, an engine hoist and is happy to help me. If I go down this route which Golf would I need to source to get that engine? (thought getting the whole car would be best to ensure engine is decent as well as getting the full loom etc)

Also apart from what has already been mentioned are there any other parts I would need to source to do the conversion?

At least going this route I should be able to get a few quid for my current engine and stainless steel exhaust and any thing I can sell off the donor golf.

Thanks guys, you're a great help and sorry for my novice questions.

[discostu117]

So I took the plunge and have purchased a Subaru with EJ20 engine to put in the van. Got RJES booked up to do the wiring and will get all the parts from him.

Does any one have any tips on which parts of the donor vehicle are worth trying to sell? When scrapping the shell has any one been successful in getting money for it or do you usually end up paying someone to take it away?

Has any one tried fitting the front seats of an Impreza into a T25 as I was hoping to do this as an added bonus?

Thanks

[silverbullet]

The 2.0 is barely worth the effort as it's not a very strong performer in a heavier camper, a 2.2 would have been a much better proposition for the cost of conversion, but that's hindsight for you.

RJES parts will eat up your budget but it's all nicely made.

What's the donor car? Everything's saleable if the prices are keen enough.

I'm doing a fair bit of seat frame mods at the moment, lots of solid welding going on. I've got a few spare bits like runners about the place. Give me a pm and we'll see what can be done with the Scoob seats, no promises!

[discostu117]

The donor car is a 2001 impreza gx estate with 91,000 on the clock.

I'm not doing the conversion for power really just a more modern, economical engine as the 1.9dg is on the way out. I'm happy just cruising at 70 and not rushing to get anywhere.

I would have gone down the GTI route, but value the thought of high quality parts from Richard rather than sourcing the required diesel parts from an old T25 even though the cost is a lot higher (Planning to keep the van for a while and the rest of it is solid).

Can I just get the runners from the existing seats welded to the impreza seats? I expect its more complicated than that.

Thanks for the help,

Stu