Converting a 1981 bus to a newer petrol motor

[eraserfish]

In my search for new a new T3, I occassionally come across a bus that it's in great shape but with a bad motor. I know there are some companies out there who will do a motor swap which usually just includes block and heads. But what if I don't fancy the original motor at all, and want something bigger like a MV or DJ. If I"m starting from ground zero with the motor then why not put something in i will really love. Are there any companies who will sell me the whole thing with everything on it (rebuilt) and maybe even accept the old different motor as a trade in? Which brings me to the next question; What are the differences in wiring harnesses and electrical between the older motors and the newer ones that I would have to worrry about. In the case of this particular van, it's a 1981 but it has the second front grill which is telling me that it's probably not an Aircooled, maybe a DF or DJ. What other things might have to be changed when swapping out an older motor with a new motor like this. Your comments are invaluable!

[bhpdub]

If it really is a 1981 with a lower front grill, it's likely to be a diesel.
Prob 1600cs engine.

[tforturton]

There's a whole section on alternative engines....in the Technical, Alternative and Modified section.

[marlinowner]

I would be tempted to buy a van with a tired diesel engine and convert to Golf gti petrol engine running on LPG.

[eraserfish]

I just got an email back from the owner. He says the motor is the original air cooled CT (1600). I looked in alternative forums, but didn't find what I'm looking for. I don't want an alternative motor, I want to convert this 1981 bus to having an standard bus motor 2.1 MV or DJ. So I guess the better question would be has anyone converted an air cooled CT motor to a MV or DJ motor and does anyone have a good link to getting one of these as a rebuilt motor with all the peripherals. If I could get a rebuilt MV or DJ with all the components for $4000 or so I could have a really great long running bus in great shape for a really low price.

Thanks,

[ghost123uk]

It's not the actual motor that is the main stumbling block, it is adding all the cooling system to a van designed as an air cooled. Radiator, heater matrix (and associated plumbing and controls) coolant pipes, front lower grill etc etc. If you are "set" on this van, have you considered one of the rather nice upgraded air cooled flat fours that are around. For the money you mention you could get a new, reliable, powerful 2.4Ltr, Twin Dell fed motor ?

[toomanytoys]

Where in the world are you???

As Ghost123uk says.. you gotta get all the bits to convert to watercooled and that's a lot of bits and a lot of work to install..

And.. although a waterboxer will bolt up to the gearbox, the gearing will be so low that it will be reving its nuts of at 60mph.. So.. gotta factor in a better gearbox..
Unless the van is really really fantastic condition and is cheap (for some reason) its a lot of work..
Are you going to do the work yourself?? or get someone to do it..??

[eraserfish]

Yup that's exactly what I was looking for, a practical answer and difficulty level. I'm a little ashamed of myself for missing the obvious about all the cooling differences. I was being a dum-dum and just thinking about physical size, motor mounts and gearing. So this is probably a no-go and I will keep looking for something else a little more road ready. Someone will get a get deal though; 1981 T3 super clean, good paint, no rust, single owner, kept in a garage, everything original, just the motor doesn't run....for 2000 Euros.
@toomanytoys, I've been in Afghanistan for a year saving my nickels so I can fall in love with a vehicle again. Usually I live in Germany about an hour from Frankfurt. The last thing I truly loved driving was my 1972 beetle....and my 1982 Ford escort RS turbo. I just hate new cars and how boring they are. I want to smile again when I get in my bus.
I've been wondering about the transmission in the buses. Exactly how many transmisions did VW make back in the eighties? I thought all the watercooled trannies were the same except for the 4 and 5 speeds.
Thanks as always for the replies; I feel like eventually I won't be stupid. Actually researching this stuff is a lot of fun, and this is a great forum.

[discipleofsketch]

I've been wondering about the transmission in the buses. Exactly how many transmisions did VW make back in the eighties? I thought all the watercooled trannies were the same except for the 4 and 5 speeds.

Ignoring the 4wd (syncro) gearboxes, there's 31 4-speed and 32 5-speed versions listed here:-

http://www.brick-yard.co.uk/VehicleSpec ... fo/gbx.htm" onclick="window.open(this.href);return false;

All pretty similar though, from what I can see!

[toomanytoys]

Similar??? But not the same... and if you pick the wrong one.. you will either never get into top gesr or never use 1st... and be flat out at 100kmh....

[faggie]

if you live in Germany you have choice of some amazing buses with loads better engines than the fragile waterboxer but if it was me and the van is as good as you say I would buy it and fit a 2400cc Aircooled motor and matching dk code gearbox

[ghost123uk]

if you live in Germany you have choice of some amazing buses with loads better engines than the fragile waterboxer but if it was me and the van is as good as you say I would buy it and fit a 2400cc Aircooled motor and matching dk code gearbox

have you considered one of the rather nice upgraded air cooled flat fours that are around. For the money you mention you could get a new, reliable, powerful 2.4Ltr, Twin Dell fed motor ?

[discipleofsketch]

Similar??? But not the same... and if you pick the wrong one.. you will either never get into top gesr or never use 1st... and be flat out at 100kmh....

indeed

More detail here, showing revs at different speeds assuming standard wheels+tyres:-

http://rjes.com/html/gearbox_types.html" onclick="window.open(this.href);return false;

[toomanytoys]

Also.. IMHO.. a 2.4 type 4 isn't the right thing to do in a bus.. (just built with bigger barrels and pistons) its in fact better to build something smaller but stroked, with the right cam in it.. that way, the heat can be got rid of more easily.. and a heavy van generates a lot of heat...

Just my opinion tho...

[ghost123uk]

Good point (and he ^^^ knows )