1.6D being changed for 1Y

[camper]

You can use the 1.6 pulleys & alternater just swop over.Fit the 1.6n flywheel & obtain a spiget bearing to fit into the crankshaft before the flywheel is bolted up.

[peteabbott]

Well done. I changed all the pulleys over but also had to use original water pump (different hose connections) and the alternator bracket. As previously mentioned dont forget that spiggott bearing (might have done this myself once ) Are you using your original inlet / outlet manifolds ? I used my originals but mine was a 1.7 KY and I dont know if the sizes 1.6/1.7 are the same but they fitted very well although the internal bores are a tad small. Nearly there, vrooom vrooom.

[nenenaiad]

Hi All,

Thanks Camper for reminding me that the pulleys bolted on. I didn't want to change anything to do with the timing until
I had got the new engine running just in case there were problems.

Anyway have removed all pulleys off the 1.6D together with sump. Looking where some of the sensors are mounted in certain water
outlets it looks as though some of the plastic outlets will have to be changed for 1.6 ones for sensor connection.

I did not quite understand what you said camper re the flywheel, was there a typo in the numbering you used?

I intend to put a new clutch in. The question is do I have to ptake the one off the 1.6 and put it on the 1.9 or can I just remove the clutch off the
1.9 flywheel and mount the new clutch on it ? I have a new spigot bearing by the way to fit. Also a new 1.6 oil pump.

Glad the wife doesn't read this.

Regards


Dave

[camper]

Sorry if i was not clear in my reply .I mean fit the spiget bearing into the 1Y crankshaft then fit the 1.6n flywheel as reminder to not forget the spiget part.The 1.6 flywheel & its clutch is correct for the 1Y installation in the T25 but not the 1Y 1.9 flywheel.

[nenenaiad]

Hi camper,

Thank you for that, all understood.

Am about to order new clutch so will order new bolts to put old 1.6D flywheel onto 1.9D.

All good fun.


Thanks again


Dave

[nenenaiad]

Hi,

In taking off the sump from the 1Y the baffle became stuck between the sump and the block and become distorted.

I am waiting to put on the old sump and the new (1.6D) pump. IS THE BAFFLE REQUIRED ?

Regards



Dave

[camper]

. There can be problems fitting the gear box end large sump bolts if you use the baffle as to cause misalignment between holes to the sump .Its due to its thickness between the sump and block.So use the 1.6n sump gasket and dont tighten the small sump bolts untill you get the engine sump large bolts gearbox end tight.Reason is it can crack the sump if pulled by the bolts if the small sump bolts are tight

[nenenaiad]

Hi Camper,

I have removed the baffle which was on the 1.9(1Y) and fitted the new gear pump (1.6D) variety on to the 1.9(1Y),
The baffle has its own gasket so I could not have retained the baffle and put a new gasket on.

I have put on the new gasket and put the bolts back although not torqued up yet.
I will leave them just slack tight enough to form a seal an wait until I have bolted the engine back in.

I had picked up the comment about damage to the sump in Bentley, and will leave the sump bolts as they are until I have put the engine back.

Did you remove your baffle, and do you know of any problems this may cause ? From what I can see the engine is basically going back to as it was,
which is without a baffle ?

Regards


Dave

[camper]

Glad all is going well for you.I didnt use the baffle gasket but used the 1.6n one and have had no problems.Question is the oil pump a direct replacement as was fitted to the 1.6n?.

[peteabbott]

I didnt use the baffle (windage plate) either and I fitted my original 1.7KY oilpump to the 1.9 and have done 4500mls problem free. Dont know if the 1.7 and 1.6 pumps are the same though ? Beware though as I read on here somewhere that after fitting the oilpump rotate the engine a couple of times as it sometimes fouls the crankshaft, dont know how this could happen but someone did have a problem so worth a check anyway. Sounds like all is going well.

[camper]

I had the problem with a shaddock replacement oil pump due to a slight clearance problem when the piston rod crank cap bolt on bottom stroke hits the pump casing.Apparently if you swop over the pick up from the VW oil pump to the shaddock its okay.I didnt but cleared off a few thou on the casing i have done aprox 15000 miles on the 1Y with the shaddock pump & its okay.

[nenenaiad]

Hi Peter and Camper,

Thanks for your comments.

Before starting this I got the parts I felt I needed from Brickwerks.

They are really good people and I cannot speak too highly of Simon who was very helpful, and had
obviously been down similar paths before. I shall order a new clutch from them over the weekend
together with some flywheel bolts.

It looks as though I will need to reuse the diecast water outlets from the 1.6D - new gaskets spring to mind and I am not sure
Brickwerks source them - perhaps best to ask. I did treat myself to a little device which cuts the circles on gaskets, but don't have any gasket material at present to make my own.

I will turn the engine over manually at some point to check for fouling with the crank.

One of the hardest things about this is that I am only using the last four foot of my garage as I have another vehicle I am working on.

I managed to use the engine lifting rig to manopuver the 1Y next to the old beast, and rest it on an old pallet. Then of course fold up the engine rig and get that in the garage.

Just thought of another question, did you both use the new cam cover that came with the replacement engine ?

Thanks for your help.


Regards


Dave

[peteabbott]

Well there ya go then I knew I wasn,t going mad. Thanks CAMPER. I really enjoy all this. what on earth did I do with my time before I got my van. Perhaps I had a mispent youth and then got the van. Doing it yourself gives a great deal of satisfaction and you get to know every bit of your van. Really it is a very enjoyable usefull hobby and if you DIY it need not cost a fortune. Roll on Summer and I really admire the winter campers BRRRRR

Oh yes, I used the 1Y cover as I am sure the KY one wouldn,t fit.

[camper]

Yup i agree DIY then the costs are kept down My next job is to fit a ebersphacer D2 to the van Ive no garage to work in & its to cold to work outside .Will leave it till the weather picks up .Oh those die cast outlets have O ring seals .

[nenenaiad]

Hi All,

I know what you mean about the cold camper, but managed to get a few things whilst the sun shined........as always some problems

Firstly, the existing water housings at the rear of the head and by the glowplug line on the 1.6D all had tappings for sensors.

The plastic one at the back of the head of the 1.9 1Y has no such tapping. I could use the 1.6D diecast one but will have to get or make a
gasket for it.......no O Ring on my version.

The plastic one on the 1.9 1Y in the region of the glowplug line has a sensor mounted in it and fed by a 4 pin plug. I am not sure if this can be
used with the existing circuitry. Once again if I replace it with the original one then we are in the realms of a gasket being needed.

Did any of you have problems with these housings ?

Regards


Dave