1.6D engine issues...

[blue]

Hi all, apologies first for a long post, but I have to get this stuff answered quickly, as time is running out, and money is tight.

I have two vans:

MAPPY: a dying but beautiful 1.7D T25, with 221000+ miles on the clock, which will become an MOT fail on October 6 this year, I can't run to the repair bill on it. Major bodywork / welding issues after several years of illness prevented me from caring from her well enough. So I bought another T25

ZEN: with a good solid body [not pretty, will need painting, but she goes, is solid, and has 12 months MOT], originally had a 1.7D, but that died, and had a secondhand 1.6D from a Jetta fitted, engine code= JK, with around 40000+ miles only on it. The van itself has done 117000+ .

Both vans are 1989 F reg, the high mileage one is May 1989, the lower mileage van, my new bus, is February 1989.

Question 1: JK engine - is it fully compatible with the five speed gearbox fitted with the original 1.7D that was in the van previously?

Question 2: JK engine - what oil capacity is correct for this engine? The seller was unclear, and I am still unsure. I want to drain the oil and refill with a new filter, so I know where I'm at, so need the magic number. Is it 4.5 Litres?

Question 3: The one with the JK engine has an oil pressure light problem, after a pair of new switches were fitted the day before I bought, it, and am still sorting it, off for a pressure test this week, and am going to try to swap the dashpod to check for that fault [she has already shown buzzer of doom issues]. The engine ruuns well, has plenty of punch for a 1.6D, due to the much lower mileage, compare to my tired but smooth running old 1.7D with 220000 miles. The JK engine is ticking a bit fast, and I feel I have some tweaking to do to get her right,

Question 4: Zen needs a cold start cable, as this is missing. [She starts and runs fine, but I couldn't get by without one] Do I get one for a 1.6D T25, a 1.7D T25, or do I need a mod for this to fit right?

Question 5: Zen needs a new exhaust soon. What back box and down pipe should I get to fit the JK engine right? Do I need a 1.6D, 1.7D, T25 exhaust, or some other combination?

Maybe Zen is a touch Frankenstein, but money is very tight, and I figure that I can build one good bus from the two, as one excels in all the places where the other fails. Once I have Zen right, I plans to sell Mappy as a repairable runner, without MOT, to someone who is handy with welding kit, unless I need the engine or gearbox [I hope not!], or would happily swap her for a running type 2 / type 3 golf with MOT.

I've driven VW buses since 1991, and had Mappy the T25 since 1996, I love 'em, and couldn't be without 'em. All help and advice will be most welcome and appreciated.

I live in Cornwall [St. Ives] and have access to a great mechanic, can do a little stuff myself, and have recently joined the CVWOC.

Cheers,
Blue

[Horza]

Coooo 220000 miles Nice one!!

Q1. What do you mean compatable? The ratios will be diferent to those on a JK box but not that much that it will cause you hassle. Look at this Brickyard table for ratios and stuff.

Q2. 4.5 litres should be right. The suggested trick is to let it all out, pour in 4.5L, run it, let it settle then mark the dipstick so you know.

Q3. What's the question then?

Q4. You could try swapping out the cable from your other van. If this works you know you need to get one to fit a standard 1.7. If it doesn't you'll have a better idea of what fafing you will have to do.

Q5. Unfortunately that depends on what exhaust the converter fitted when it was done. You could compare it to your 1.7, look at the drawings on Just Kampers or try to look at an Etka or some such to see if it's the same. It may have fabricated bits in it though and you might have to find a nice man to make some of it for you.

[blue]

Thanks for the reply Horza...

221000 miles now. It will be sad to see her go. But hopefully someone with more money than me will save her one day soon. I had her from 73000 miles, and I 've enjoyed every last mile of reliability. That's why I'd never buy another type of van, tried, but couldn't do it. Just goes to show what regular oil and filter services can do for your engine. Keep 'em running sweet boys and girls...you too can break records with your mileage.

1. Sounds compatible then.

2. Will do this as soon as it stops pouring with rain then, which will be Saturdayish.

3. You're right there...no question!

4. Here's hoping it's a straight 1.7D cable. Depending on price, may just get a new one and mod it. Remember, I'm trying to keep Mappy to sell / swap as a runner. Hope no faffing required. Hate to faff!

5. Bit suss on the exhaust issue, as it's been repaired to get the mot, which makes me suspect a tricky job. Needs a closer look, meanwhile, think my new pet mechanic might be able to help with getting a good fit at a reasonable price. He ain't no robber, and he would qualify as a nice man who might just help make one up, although come to think of it, he's no welder, so a little research will be required here. Hmmm.