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Hello
Sorry if this question has been asked a thousand times before. But my 1.6D blew up (on the way home from buying it) So I thought I would swap it for a 1.9TD AAZ.
I haven't the time to do it myself so will be getting a very good local garage to do it for me. If I find and buy a engine is it a straightforward swap? Will parts from my engine swap over and should I source a gearbox with the engine?
Any help gratefully received.
Regards
Jon
Where to begin? Everyone always starts with the big question - MTDI or ETDI? Once you know this answer you'll know your next move. Believe me, I had 12 months to make this decision and I've gone down the MTDI route. Why? Because I hate computers and anything with a PCB inside always gives me grief. Well that's my defence! Let us know which way you intend to go.
Right now I'm in the middle of my AHU conversion. Engine is out and the gearbox is with Aidan Talbot for lengthening.
So far I think it's all going to come in under £4,000 by the time I've finished. You can do it a lot cheaper but when you make reductions the end article is never going to be as good.
Sometimes it's better and cheaper to repair / exchange or swap the old unit if you've been caught unaware as you have.
Like I said, I have planned my TDI for over twelve months and its not something you should rush into.
Busfest is coming up in a couple of weeks perhaps you should attend with the intention to ask as many questions as possible to gain the experience from members of the vw t25 community who have achieved the goal.
regards
Why does everything I "want" - scrub that, need - cost so much?
Jon, I'm not familiar with the 1.6D, but I think you'll need some of the 1.6TD (JX) bits, eg. ex. mani/turbo, inlet mani plus pressure duct (then of course you may want to consider an intercooler), sump (which has the turbo oil connection, but you can mod a D sump). Most folk find the AAZ benefits from oil cooling too. What to do about the pump depends on what you get, some have no LDA so you may want to swap that for a better one. There's a good guide on BY. Baxter posted an enhanced version on here recently which might be worth searching out.
Syncrosport (taking a break as of summer 2024)
Volkswagen Transporter, reloaded.
To convert to an AAZ TD from 1.6d as already mentioned you'll need some parts from a JX 1.6 TD. It's fairly straightforward, but i'd be looking for a specialist garage if not doing it yourself. Hardest part would be finding a good AAZ, as they are old engines and not so readily available.
VirginAtlantic mentions tdi engines - that's a whole other ball game, definitely a specialist job with more bespoke work.
Former owner of 1983 DG panel van and 1983 Devon moonraker pop-top, 1.9 tdi (1z) conversion
toomanytoys wrote:Oh and 1.6 non turbo gearing will be a bit short.. 65mph flat out.. reving ins nadds off...
Good point, I have just done a deal for a five speed box which I have now decided to put a 1.6TD with rather than a AAZ. As its going to be cheaper and get me back on the road quicker.
Hoping I have made the right decision.
Right now I'm in the middle of my AHU conversion. Engine is out and the gearbox is with Aidan Talbot for lengthening.
We're getting ready to put in our remanufactured AAZ into my 1.6d, got most of the bits we need but I must admit I've been thinking about the gearbox as I am aware it will be rather short for the 1.9 TD.
Is it the whole box or can they just lengthen 4th for example? Im aware getting a box modified can be very expensive, can any other boxes be used?
Cheers,
Matt.
1985 1.9TD AAZ -Starlight Interior
2015 California Beach
Regarding gearboxes. The two choices I was made aware of was Aidan Talbot T25 Gearbox specialist http://www.aidantalbot.com" onclick="window.open(this.href);return false;. he'll use your current vw box and rebuilds it to your spec and repairs too.
Brickwerks http://www.brickwerks.co.uk/index.php/" onclick="window.open(this.href);return false; for materials ie imput shaft, spigot bearing (Very very important for TDI engines you'll be a plonker if you don't fit one!) C&P 4.14.
Now http://www.ultimate-engineering.co.uk/" onclick="window.open(this.href);return false; Tim Shettle has adaptor plates for Renault gearboxes to vw engines you'll have to do your research on this installation as I have no idea on this type of conversion or of the results. Tim also makes turbo adaptor plates also well worth knowing and a great product.
regards
Why does everything I "want" - scrub that, need - cost so much?
VirginAtlantic wrote:Where to begin? Everyone always starts with the big question - MTDI or ETDI? Once you know this answer you'll know your next move. Believe me, I had 12 months to make this decision and I've gone down the MTDI route. Why? Because I hate computers and anything with a PCB inside always gives me grief. Well that's my defence! Let us know which way you intend to go.
Right now I'm in the middle of my AHU conversion. Engine is out and the gearbox is with Aidan Talbot for lengthening.
So far I think it's all going to come in under £4,000 by the time I've finished. You can do it a lot cheaper but when you make reductions the end article is never going to be as good.
Sometimes it's better and cheaper to repair / exchange or swap the old unit if you've been caught unaware as you have.
Like I said, I have planned my TDI for over twelve months and its not something you should rush into.
Busfest is coming up in a couple of weeks perhaps you should attend with the intention to ask as many questions as possible to gain the experience from members of the vw t25 community who have achieved the goal.
regards
AAZ is niether mtdi or etdi...and is about as simple as engine swaps go...bigger tyres are the cheapest way of lengthening the overall gearing...and as stated above finding a good AAZ is the tricky part..but they are a good engine when healthy and fairly happy revving away in the back compared to a tdi.
Regarding the gearbox - I put a 1.9 AEF (non turbo skoda felecia) onto the standard 1.6CS 4 speed gearbox and with bigger tyres (215/80 14's) it runs just fine.
Steady 65 mph (sat nav 65 mph) all day on motorways without over revving the engine.
I understand (and am ready to stand corrected) ....... that the 5 speed box in 5th is same ratio as 4th on the 4 speed box - so if im correct then there's no advantage to be gained installing a 5 speed.
Hope this helps and very best of luck with the conversion....its certainly best thing I did to my van once bigger tyres were fitted, we covered france all the way to italy/swiss border last month , it ran sweetly and kept up with modern traffic speeds without stress
If starting from a 1.6 cs the two easiest/quickest/cheapest options, both with great (but very different) results, are the 1.9 1Y or AEF N/A diesel, or the 2.0 8v AGG petrol.
1Y is a great budget option. Very straightforward swap with the CS, and would go well with the original gearing but bigger tyres (as matt said above).
Next stage up, and the best option imho, is the AGG. There's lots of info on here and brickyard regarding the conversion. Great driveability, but for diesel-beating economy you'd need to go LPG too. Gearing wise, best to swap to petrol box with diesel bell housing and input shaft. Ok, it's a more expensive job than the N/A diesel, but makes for a very nice van owning/driving experience, and cheaper than a tdi!
The Campershack - (website paused) WBX Rebuilds & Upgrades from the beautiful Isle of Arran
So I thought I would swap it for a 1.9TD AAZ. 
