Big Daves 1.7ky-1Y Motor Conversion Thread!

[covdubber]

Man i'm shattard! i need swarfega! lol!

i'll load some pics tomorrow i'm to tired & cant be arsed :O)

well this afternoon was spent stripping the bits of the 1.7ky, i had a few probloms like i said before such as the broken exhaust stud which i drilled out & i'm just going use a nut & bolt to replace it! the other 3 studs aree still useable!

i cant see how i'd go about drifting the non return valve out of the old 1.7 diesel vacuum pump??? i have got the pate off which was a big ballache! the bolts were corroded so it was an a*** to get off but got there in the end

one of the allen headed bolts on the clutch pressure plate went up the swanny which could have caused all sorts of probs but i used a tool i got from machine mart! they are IRVINE ROUDED bolt/nut removers! when you put them on a ratchet & turn them anti clockwise they cut into the head & turn the bolt!
so the result is i just need one bolt for holding the pressure plate on, i have allen headed bolts of the right grade in the garage so no probs there!

i've decided for simplicitys sake i'm not going to bother with the 1y breather pipe, just due to the fact i have the blanking plate from the 1.7ky & i want to keep the motor as un cluttered as possible!!!!

i'll start putting the 1.7ky bits on the 1.9 1y tomorrow afternoon, i need to order a few bits n pieces from wither brickworks or JK so there the only bits i think will hold me back fom getting the engine back in!

i estimate i'll have the motor ready to drop back in wedensday "weather permitting"

i have put the 1.7ky crank pulley on & the water pipe that go's from the cylinder head to the water pump! & the only bits i need to remove from the 1.7 is the blanking plate, sump & oil pump!

As i say i'll sort some pics & a decent update tomorrow, i need a "kip"

cheers for the help so far you know who you are by PM & weldore!

top chaps

[weldore]

wait till its up n running..all that hand washing will have been worth it.

good luck for wednesday

[covdubber]

Well chaps n chics i've been a bit caught up with other bits n bobs but i have the 1.7 bits on the 1y motor

My advice to those of you wanting to do this conversion what i have found so far is all the bits you use from the 1.7 or should i say doner diesel engine you need to use everything down to the nuts n bolts!

an example of this is when you swap the oil pump over for instance you need to use the bolts from the 1.7 to bolt it to the 1y, or another example is the intake/exhaust manifolds, you need to use the 1.7 bolts to hold it all in place, it'll make sence when you have a fiddle swapping the bots over youself!

anyhoo! as for where i have with my conversion its is this!

all the bits are swapped over, i took the engine out of the garage & sprayed a load of de-greaser over it & gave it a jetwashing & its cleaned the motor up a bit better

i will say those £20 b&q jetwashers are a bit weak in the water pressure jet they deliver, my previous jetwasher was a b&q own brand that was a red colour & cost £30 & that is loads better than the green ones that are on offer at the moment! i'd advise getting the £30 ones! far better

anyway its in the my old-mans van & we are going to al least get the engine bolted in tomorrow morning!!!

i gotta swap my new clutch slave cylinder onto the gearbox first but other than that the aim is to bolt the 1y motor in tomorrow morning! :O)

i'll get the pics of some of the modifications to the 1y motors needed to do the swap but the mods needed are minor easy things to do!

Once the engine is in then hopefully i'll get the coolent bled through the system & oil in! i'd like to get it started & up & running if possible

it would be nece to have it running & on the road over the weekend so i can run the engine this week daily, tweak what needs tweaking & take it down to VANFEST

if anyone has any advice at this point or any questions dont hesitate to fire away!

[weldore]

just run it with plain old water in the system till you know its leak and problem free then add the antifreeze
make sure your battery is fully charged
drink copius amounts of what ever is your tipple when it fires up

[covdubber]

weldore is it just a case of hooking up the 1 black wire that go's to that solinoid in the middle of the pump where all the fuel lines come out for the pump to the injectors???

oh & hooking up the glow plug wires as per the 1.7ky?

yep i thought the same as you've said weldore, just run on water untill i know its leak free etc etc

i'm super nervous & crapping it, why, i hope the motor is a good runner, it turns over with a spanner on the crank nut & i can feel compression!

the glowplugs are new & the vehicle its going in was driven to its destination where i took the motor out!

i've used all the 1.7ky cooling sytem hoses/connectors on the 1y engine the 1.7ky water pump/alternator bracket & alternator, basiclly its only the block & cylinder head that are from the 1.9 1y!

i have a new clutch too!

its the pump wirng i'm still a bit iffy about

oh yeah the other thing i have use from the 1.7 ky motor was the fuel pump feed & return banjo fittings & put them on the 1y diesel pump, when i get the pics up it'll make sence why i done this!!!

[weldore]

you prolly have done it by now but as far as im aware you just use the same wire to the pump that you did on the old engine..if yours has the black box thing with a few wires coming from it under the solenoid then it might have an imobiliser built in ..i didnt have one on mine but a search through Ringo's posts in the wiki will help you out with that
the glow plugs..again the same as before
i was crapping myself too and then the battery died as i was trying to get it running..so make sure it fully charged oo(mine turned out to be a fault on the starter though)

[peteabbott]

I had to prime my pump by filling it into the big banjo connector as the pump was bone dry and would not prime by itself. There are 2 solenoid looking things on your pump, the one in the centre of the four injector pipes is an electronic thing that would normally go to an ECU so you can ignore that one. Just to check the solenoid is working turn on your ignition and when you put the wire on and off you will hear it click. Nearly there mate, I will stand in my front garden and keep an ear in your direction for a vroom vroom.

[peteabbott]

http://i245.photobucket.com/albums/gg41 ... ine012.jpg" onclick="window.open(this.href);return false;

Can you see it ? Is it the same as yours ? As you look at it it is the one to the right of the DTI. NOT the far right as that was the original electric coldstart that I replaced with the original 1.7 cable........lovely. The smaller wires off that little white box was also for an ECU so forget them as well.

[weldore]

mines not like that pete..it dont have any of the extra solenoids or wires that yours has and has a manual cold start mech ..but..it did have the damper thing on it and it was a little taller than the old 1.6 pump...weird eh.wonder if its been a bodge up or its just an earlier type.it looked original mind

[covdubber]

well my Goodness! what a fckin mervin the monkey, total utter "bar-steward", shower of "pooh" of a job putting a diesel engien in a t25 is!!!

On a good notw the 1y motor is in the van, i have to hook up all the electrics/throttle, cooling system & see if it starts but its in!

Had a few probloms such as the clutch slave cylinder i git from GSF had a wanky thread so that held me up an hour as i wanted to put tht in whilst i had easy access to it sitting on a small stool in the engine bay GSF were as good as gold & could see it was'nt a prob caused by me it was just badly machined & swappeed the part for me!

my other problom was my Old screwthread type engine hoist stripped its threads with the weight of the diesel motor! to be honest it had a lifetime of work already lifting old jag & triumph straight 6 cylinder engines & i've personally lifted about 6 engines with it & i had a funny feeling it may break!
that was another 1.5hours wasted!

i nipped up the local hire shop & they sorted m out with one of those MODERN Hydraulic engine hoists! chrikey its a world apart from my old screwthread type that was originally made on rowely regis!!!!

anyhoo after ALOT & a mean ALOT of swearing by myself & my old-man at the engine/gearbox, at the hoist, at each other, at everybody & every thing in sight we eventually got the engine in which took us a full day in total, from 9am to 5:30pm but we were held up by various probloms!!!!
i got my 2.0 Aircooled in my t25 devon in 20 mins!!!!! with just a jack on my own!

so i'll get all the bits n bobs i can hooked up this weekend!
be patiant for pics folks i i'm taking a fair few in a "sort-of" sequence! of what i've done

what do i have to change with the throttle lever as in my crewcab nothing fouls anywhere? for some reason on the normal t25 i keep thinking the throttle lever hits the engine lid or have i got mixed up in my head with somat else?

i'm getting there, slowly but surely!
as terry wogan says "slow n steady wins the race"

[covdubber]

right! as i say i do actually think iam retarded with wiring so borrowing top man pete abbots picture have i got the right solinoid in the picture, its in red marked startup, i'm not good with MS paint!



as for the glow plugs is that just hooked up as per the 1.7 as thats what i was planning to do

the throttle linkage, will that just hook up or will i ordr the linkage arms from BRICKWERKS for ease of setup?

if i have the wires wrong in the pic above lpease modify

any other hints n tips guys to get me going

once i get the motor to start (hopefully shes a good motor) then i'll bleed the cooling system as per simons guideo n brickyard!

pheeewwww so far

damn i need another tub of swarfega! & brown sugar :O)

[covdubber]

got the water pipes all hooked up this morning! also fitted the 1.7ky oil fille pipe! got the 1.7 airbox fitted also

still unsre what connection is the one i need to hook up to on the diesel pump?

i have a small white box thing about 2cm x 2cm on the bottom of the pump with a black wire & brown wire, there is a solinoid with a yellow wore & a green wire "i think" i did'nt have my glass's on :O/ there is a black wire to a solinoid which is sort of right in the middle of the fuel pipes
there is also a solinoid above that that is in the same metal casting as one of the fuel banjo fittings????

also i forgot to ask? do i use my old 1.7 oil pressure senders??? ie the one in the cylinder head & one in the oil filter housing? or do i use the 1y senders?

& to confirm! these motors need 4.5 litres of oil dont they?

whats the best way of starting it as the diesel has drained from the feed/return pipes now, how do i bleed the fuel through, do i just loosen the pipes that go the the diesel injectors & crank motor untill fuel leaks past then tighten the unions?

will it take much cranking to start? i only have a small battery! i have charged it up!

be nice if i could get it to turn over tomorrow if you chaps let me know the solinoid i need to hook up too, i'm a bit lost on which one it is?

i've made some space on my phone to do a video of it running if it starts ok


i better put the exhaust back on too had'nt i

[peteabbott]

http://i245.photobucket.com/albums/gg41 ... ine012.jpg

Can you see it ? Is it the same as yours ? As you look at it it is the one to the right of the DTI. NOT the far right as that was the original electric coldstart that I replaced with the original 1.7 cable........lovely. The smaller wires off that little white box was also for an ECU so forget them as well.

[peteabbott]

I had to prime my pump by filling it into the big banjo connector as the pump was bone dry and would not prime by itself. There are 2 solenoid looking things on your pump, the one in the centre of the four injector pipes is an electronic thing that would normally go to an ECU so you can ignore that one. Just to check the solenoid is working turn on your ignition and when you put the wire on and off you will hear it click. Nearly there mate, I will stand in my front garden and keep an ear in your direction for a vroom vroom.

[covdubber]

got the slave cylinder bled through today! clutch pedal & cylinder seem to be working well, the old fluid is coming out is a bit dirty so the fresh fluid flushed through is defo a good thing, seems to have a good "pedal" my old man & myself are gonna give it a 2nd flush through before it hits the road, & i've got a gunsons easy bleed so we'll hook that up & flush some new fluid into the brake circuit too! open the bleed nipples on the front & rear brakes so all the fluid is clean & fresh!

i think i've realised which is the solinoid i need to hook up too! so jobs to do tomorrow are

hook up the wire that operates the solinoid that starts the engine
hook up the fuel lines to the fuel filter
tighten the bellhousing bolts & the pulley allen headed bolts at the front of the engine
hook up the vacuum pump non return valve to the servo line
fill it with oil & as much water as i can get in it until the engine starts
fit the exhaust
fit the battery
give it a check over of everthing

& see if it fires up fingers are crossed, hope i can get all the above sorted tomorrow!!!


let me know if i've missed out anything my heads all over the shop trying to be sure i've checked everything!!!

really nervous about it all now!