1.6 cs to 1.9 1y, help anyone?

[t25 sam]

Hi all,
i have recently bought a 1.9 1Y engine out of a vw caddy van,
my van is fitted with a very slow, smokey and oil consuming 1.6 cs(so i have all the relevant manifolds, sump and other conversion parts) but, and i hate to seem repetitive, (as there are many a thread on the conversion) i know that by trawling the numerous informative threads and websites i should get a rough idea of what the conversion entails,
but i cant seem to find a start to finish, step by step, all in one guide to getting the 1y in all cushty , to overcome any problems that may be present,and that lists all the extra bits and pieces needed all in a single thread,(and to put my mind at rest at what i have let myself in for ) ,
im going to get a friend to aid me in adding a new cambelt kit, relevent gaskets are going to be replaced while the engines free standing by myself, and i might give it a little clean to!
I am a beginner 8090s member, a beginner Amateur mechanic, although i know a little, and i would really appreciate any help that anyone could donate to me,
thanks all and hope to hear back,
regards
Sam

[Oldiebut goodie]

Did you peruse this thread? https://club8090.co.uk/forum/viewtopic.php?f=12&t=107034

[ringo]

Best thing is to write down your plan of attack here - and then folks can comment on what you are doing (or aren't doing).

As you say, there is lots of info so do your research and feel free to ask more specific questions.

Good luck,

Ringo

[t25 sam]

Thanks for the quick reply oldie,
and i did (to a degree)............
I was really hoping someone would post a one page, numpty friendly , abc 123 listed example of what they did, what the overcame, and the minimal parts needed, so i could basically print the page of and keep it on the bench to refer to, i know the engine and bus might be slightly different in there own rights, but i am hoping to have a pretty set standard of guidelines to work to, and for it to go pretty straight forwardly... as i don't want to be put of with doing my own mechanics,as this would probably last a lifetime i don't easily give up but sometimes i can let things get the better of me,

Ringo, that sounds like a good idea,
i think the best thing i can do for now is get my engine out, for what i can see as being the easy part, and see how far i can get with it,
many thanks, it really is appreciated!!
sam

[vwmaddy]

Hi i havejust done this conversion myself without any previous experience

so drop me an email at vwmaddy@hotmail.co.uk and ill talk you through it

dont be worried its not a bad job to do we would have had it done in a weekend if my exhaust manifold wasnt cracked so we had to make a down pipe

cheers

[t25 sam]

Cheers buddy!
and a big shame on that manifold, what did you end up doing? did you source a fresh one?
I have stripped the 1y down leaving the alternator set up as is, just removed all other ancillaries ie power steering pump, starter motor, gearbox, clutch etc just wondering if the standard alt setup will cause me any problems and is it purely the quickest and easiest method of just getting the engine in and running?
Also i have noticed on a quick examination that the fitment for the breather pipe on the block, the plate with the two bolt holes, has totally de attached itself from the pipe,
it looks like there has been some serious leakage from it so i think it must have been going for a while, i have noticed tho that some people have blocked this breather off? but is a breather not there for a reason? has anyone got any advise for me on this?
hoping to get my old engine out in the next few days, if it stops snowing!!

[vwmaddy]

Hi i used the alternator setup on the 1y with no problems

i used the 1.6d inlet manifold blocked of the egr hole

fixed the old and new breather pipes together

one wire to pump solenoid and away she went

ended up using the 1y manifold with downpipe then attached to existing exhaust with a flexy

just remember to fit a spiggot bearing before attaching gearbox

mines all up and running just deciding whether to put the expansion tank back in or run the system as the 1y cooling setup

can send pics etc through email

will update that bit ater this week

[Oldiebut goodie]

Also i have noticed on a quick examination that the fitment for the breather pipe on the block, the plate with the two bolt holes, has totally de attached itself from the pipe,
it looks like there has been some serious leakage from it so i think it must have been going for a while, i have noticed tho that some people have blocked this breather off? but is a breather not there for a reason? has anyone got any advise for me on this?

If you look in the thread that I steered you to you will see that I fabricated a steel replacement for mine as that plastic seems to be a weak point on these 1Ys, also one of the plastic coolant flanges had retired early - this was replaced with a normal alloy one. Some say that you don't need the crankcase breather but my feeling is that as it was there on the original engine I would keep it.

[t25 sam]

Right then, got a gap in the weather lol so cracked on ripping the 1.6 out, battery off, coolant dropped, air box removed from top of manifold, one allen key was more than round so i gave up that idea for now and as i usually forget where things go approx 5 secs after unbolting them, i put back what i could, iv labeled every wire, drew a diagram of the coolant system(before i took the hoses off) and im now i think ready to crack on unbolting gearbox and mounts, one thing tho, after unbolting gearbox, am i better to simply support the engine weight with the hoist, unbolt engine bars from the chassis and work that sucker out? or will say the drive shafts stop me getting the play needed to separate the gearbox from the engine? can anyone advise me on this? im working the weekend then cracking on monday, so hopefully i can have the bits of the cs needed for the 1y Monday afternoon.

Also iv been pricing the bits i know i need up, but can anyone point me in the direction of the right spigot bearing i need, iv looked on gsf, they have two listed, im thinking its the pricier one at £5 something, does anybody know of hand what size the correct bearing is?

also for the 1y would mineral be better than semi synth?

and one last thing for now, do i use the vacuum pump for the brakes that is still on the 1y?
thanks again for the input

[shaka1976]

Read this thread

http://www.brick-yard.co.uk/forum/16cs- ... 600#426837