for questions and answers about alternative power transplants on the T25, GTi, Porsche,Subaru etc, this is the place. You must register to post but anyone can read.
weldore wrote:yes use a suitable drift to push it out from below
if your goimg to use the old setup then swap the waterpump body too
Thanx for that i will have a little look, i think i have caused my self a big headache!!!!
Removed the bottom pully after having some trouble undoing the bolt only to find that the bottom timing belt sprocket came with the pulley!!!! GRRRRR!!! i didnt wanna play with the timing belt side of things till the engine was in the van!!!
So how do i go about re timing my engine? i understand that the cam gets locked off, the fuel pump lines up with a mark on the case/bracket and then gets locked off, but how to i position the crank as i dont have a flywheel on it yet and obviously it isnt in my van?
This stuff is sent to try us......(or slow us down i think is more to the point! )
Hello, i had this when I did my swap. I found that if you remove No.1 injector you can actually poke a stiffish bit of wire through the hole and when you spannere over the engine you can "feel" TDC. (it is easier to remove No.4) as 1 & 4 are TDC at the same time as long as you have the camshaft locked in the correct place....both cam lobes on No.1 sticking up with both No.1 valves closed, pump pulley locked in position (hole through pulley into pump casing) on with your belt and tensioned. Remove all locking bits, spanner over a few times, check and recheck.
Link here to previous post might be helpfull.
Well impressed with performance&fuel economy 35 + mpg since fitting the 1Y manifold .The egr casting which has been blanked off could do with cutting & welding to give clearance for the camshaft cover to be taken off.Agree the manifold could be ported as there is plenty of weld reinforcement to shape out but thats for another day .
Thats an interesting question about what percentage in performance.I went on hols last week with the 1y manifold & custom universal airbox fitted to the engine.Driving from Surrey to West sussex the roads are a mix of straights and bends & Bury hill in Sussex which is a bit of a climb .Its hard to put a figure on it but i would say 10% extra torque noticable second gear climbing bury hill & not having to change down to first.Between second & third on a straight the van pulls strong with a DK code gearbox & going into fourth 55 to 60 mph is a breeze as the van keeps pulling. Well worth it oh i noticed the temp gauge is lower . If any one wants ally welding done in the south east http://www.arc-tig-weld.co.uk/home" onclick="window.open(this.href);return false; . Rates are very reasonable.
A few picts of the manifold the airbox fits nice & snug behind the back light.Cut and blanked off the egr casting to not interfere with removal of the cam cover.
.I decided to cut 30mm off and get it aly welded .Thinking about this are there diffrent 1y inlet manifold sizes and it was my bad luck to get one that wouldnt fit?.All sorted now so not a problem .
Last edited by camper on 08 Mar 2012, 08:15, edited 2 times in total.
Finally managed to get the old lipstick oh and the new one fitted, used an oilite bush 12km ex dia, 8mm int dia, put in the freezer for an hour and it all went together nicely. Next problem is that the alternator pulley isnt lining up with the water pump, can I shim the alt pulley?
Got the dipstick and alternator sorted anyone got any ideas how to undo and remove the cold start cable? Surely I dont need to remove the pump to do this?
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..but i just ordered one off the bay of fleas 
A few picts of the manifold the airbox fits nice & snug behind the back light.Cut and blanked off the egr casting to not interfere with removal of the cam cover.