aaz can I do this on a 4 speed gearbox?

[steamboatbilly76]

I've finally bitten the bullet and bought a 1.9 aaz engine, 102,000 miles full-service history - i haven't a clue how to fit it to my camper which is a 1.6 td so if anyone knows anyone who could do this near portsmouth i'm all ears.

The thing is now my van is a 4 speed currently does this mean that I have to change the gearbox?

I've been reading all sorts of threads and I read oil cooler needed etc etc.

Is there a shopping list of what I need now - I'm not madly into speed if I can go 65mph i'll be happy.

This has skint me and I've a feeling it's gonna cost more =(

Any help please

Billy

[Chops]

A ballsy approach to an engine conversion. I like it.

http://www.brick-yard.co.uk/VehicleSpec ... ds/aaz.htm

As a starting point have a look at the link above.

[steamboatbilly76]

cheers chops

umm that seems pretty straight forward ..... Not, only kidding should be an ok job that makes some good sense .... I've got till may to get it right...

Still doesn't mention the 4 gear box scenario .... any more takers

I can feel a new driving van coming on +)

[lloydy]

Be fine on a 4 speed, it only has 5bhp and a fraction more torque than a JX. Was/is your JX broken?

[steamboatbilly76]

JX engine has been nothing but a pain in the ass - eats oil - 4 litres in 400 miles - that said drives like a dream - had it gone through with a fine tooth comb and it appears that the only explanation now is the crank shaft is running at an angle therefore creating slap in the piston which has scored the barrel - it doesn't smoke or anything very weird - got a one owner aaz so thought this would be the best option I'm fed up of it _ don't want more speed but not losing so much power on hills would be useful - i do 15 - 20k miles a year.

Thought my JX is good for dining

MP

[colinthefox]

JX engine has been nothing but a pain in the ass - eats oil - 4 litres in 400 miles - that said drives like a dream - had it gone through with a fine tooth comb and it appears that the only explanation now is the crank shaft is running at an angle therefore creating slap in the piston which has scored the barrel.

MP

And could anyone explain how the crankshaft can run at an angle? And that create create piston slap? And that cause a scored barre? That sounds like drivel to me! But then I'm a sceptical old dog.

If I had that kind of oil consumption, I'd have a good look at the turbo oil seals and oil return before I condemned the whole engine.

[steamboatbilly76]

Colin you wiley old fox

Had the turbo taken out, rebuilt still no joy, had it taken out and rebuilt again and still no joy, I'm still not convinced like you, but with the new engine mine will soon be a 1.9 pop top _ will sell the 1.6td needs someone to have a sort through once it's out - this problem is ongoing has been for a year and a half _ i'm at my wits end it's made me hate my van ahhhhhhh prior to this one i had a t25 for 6 years never skipped a beat ...

[Aidan]

high oil consumption may well be because the oil seperator valve on top of the rocker cover has failed allowing oil to pass when turbo on boost into the intake system, they fail quite regularly

got a used one here, that may work or may not, I can't say as the engine was blowing oil out of the turbo when it came in for a TDi swap, but I can send it out on a pay for the postage and pay for the valve if it sorts the problem basis - I don't have adiesel here I can test it on, filthy things imho

better than swapping out a good working engine unnecessarily

the 4 speed box ABH will be fine with an AAZ

[dekhelia]

The 4sp box will be fine - the bellhousing is the same as the 5sp. Wouldn't be surprised if the bellhousings were the same whatever engine was in any given Transporter shell.

The swap to a 1.9TD is a very straightforward job. I am able to say this with the benefit of hindsight only; at the time, certain aspects of it were a pig (not least taking out and putting in these incredibly heavy engines without an assistant) that I would approach differently next time.

As others have said, the 1.9 doesn't offer all that much on paper, compared to the 1.6. But the subjective experience is a great improvement. It just drives about with a lot less 'effort', it seems to me.

My only advice would be to do all the jobs to the engine while it's out. Seals, gaskets, all that - might as well replace them all while it's an easy job, saves an aching back later, and you know you're not going to get leaks. Only thing I didn't do was the head gasket - firstly because it wasn't leaking, and secondly because it doesn't look all that different a job with the engine in place.

I read a fair bit about injection timing, and generally about how diesel engines do their thing, before I started. So I was feeling confident about the principles involved.

Good luck with it.