Swapping 1.6 CT (Aircooled) for 1.9 DG (watercooled).

Post by **www.charitytour.co.uk** » 19 Feb 2007, 13:04

Hi all,

Firstly.... thanks to everyone for being so welcoming to us yesterday at Dubfreeze

. We are disappointed that the camper never made it and that we missed out on a night of camping and getting to know you all! Maybe the camper will make it to the next one (fingers crossed

)!

Thanks for all the advice on our engine woes..... we had a long discussion regarding our problems on the way home. Having weighed up all the options we have decided to swap our crappy 1.6 CT for a 1.9 DG watercooled.

I'm after some advice on how easy this change will be (I looked through the "Vehicle maintenance for women" book I won in the raffle but it didn't give me the advice I seek!

)... I know that swapping them should just be a case of bolt out the old one and bolt in the new one but what extras are needed for the watercooled?? Where does the rad sit? I've got my eyes on a couple of 1.9 DG's on fleebay, one in particular has everything with it including the gearbox.... a couple are very local to me and hence would be very convenient. Pretty confident I'll be able to do the change myself but I want to make sure that I'm prepared and have everything I'll need.

All advice and help would be gratefully recieved.

Thanks

Gareth

(P.S. Does anyone have any bullet proof vests going cheap as Matt is now petrified of gun toting russians called sergei robbing us following Marcus's russian road experience stories!

)

Post by **toomanytoys** » 19 Feb 2007, 13:13

Now. dont take this the wrong way.....
Be very carefull about how much you spend and what you buy.. any second hand engine could be a bag of trouble.. unless you know the source and they can actually prove how good it is...

its a lot of work to go from an Aircooled bus to a water cooled..

As mentioned before, easier would be to fit the 2L Aircooled, engine and box..

Who is going to do all the swap?
You might want to consider buying a ratty bodywork but good runner van to get all the watercoolrd bits off.. speak to Mercus or any of the other breakers types on here..

So many time these things will end in a lot of cash spent and unfinished/problems that tear your hair out..
Now it is possible that someone could offer to do all of the swap for you.. but again at a price..
How much do you think its going to cost?? and how much can you spend??

Post by **T'Onion** » 19 Feb 2007, 13:18

why not swap the 1.6 a/c for a 2.0 a/c loads easier

a/c to w/c loads of parts needed , rad (up't'front), the heater (dash out), all the pipe work , all the wiring, different instrument custer, expandtion bottles, etc etc etc , oh and cutting the grill vent out of the front , and a lower grill ... it is do'able but loads of work ,

Post by **ermie571** » 19 Feb 2007, 13:20

ummm - a HUGE job I would have thought.

can you not find a 2lt cu....having owned both an Aircooled and water, for the watercooled change over you will need
engine
coolant pipes, in engine bay and front to back pipes x2 and tanks x2 (header and top-up) - and a thermostat for the water!
Internal heater matrix and pipes (again front to back x2)
water pump
rad (sits in the front in the big void behind the plastic grill)
new dash (a/c doesn't have temp sensor)
new electrics (for above stuff)
cut the front panel to take lower radiator grill
and bucket loads of patience!!!

I know someone has done it on here....sure someone more technical than I will be along shortly....

edited - told you - two replies in the time it took to compile this!!!

Post by **www.charitytour.co.uk** » 19 Feb 2007, 13:38

hmmmmm..... more work than I originally expected!!! Time is of the escence and hence it looks like this would be a step too far! Working on quite a tight budget..... At present we could stretch to £400 for an engine and box. What ever goes in has to be reliable and have a bit more muscle that the 1.6CT.... we are going to be doing thousands of miles in a 2 week time frame!

Maybe changing to the CU engine & box would be a better choice? Anyone know of one that is up for sale (reliable & good condition to just bolt in). Whilst speaking to Rich yesterday he reckoned there was someone selling a good CU but that they are up in Scotland?

Thanks

Gareth

Post by **richnewton** » 19 Feb 2007, 14:08

i'm pretty sure george ( http://archive.club8090.co.uk/profile.p ... file&u=107 )has one for sale, give him a ring.

Post by **www.charitytour.co.uk** » 19 Feb 2007, 14:33

Thanks Rich..... I'll give him a shout.

Post by **badger** » 19 Feb 2007, 15:29

Deffo 2.0 Aircooled is the way to go - swap it out in a day and then start getting some miles under the belt to make sure it's reliable. Both Rich & myself have taken the same route and ditched the 1.6CT.

Post by **toomanytoys** » 19 Feb 2007, 17:13

I think, you are trying to be a little too economical...

Yes it is possible to run these vehicles on a tight budget, especially if you can do the work yourself.., but eventually you have to spend money at least on parts...
and feasable to do that locally, but if you want total reliability it will cost...
Invest some money in a good breakdown/recovery policy...

I helped a guy out last year, he had broken down, got recovered to a garage and they charged him over 1000 euro to "fix" his T25 syncro, fitting a new driveshaft and fit a new clutch, the vehicle still could not be driven as it was the gearbox that had broke, not the clutch or the driveshaft.. in the end I got hold of a 2wd gearbox and fitted that for him, he was still running around on that box last month.. all in all it cost him over 2000 euro in parts and telephone calls (they were 400 odd quid) and hassle, 3 weeks off work too and not earning any money...

Post by **www.charitytour.co.uk** » 19 Feb 2007, 17:22

Well.... the plan is to fit a replacement engine myself. I'm pretty practical and good with mechanics. I've pulled apart larger more complicated engines and removed and refitted engines (however I do not claim to be in any way an expert!). I actually quite enjoy it! (more fool me!).

The plan before we depart on the big tour is to have her properly looked over by someone who knows exactly what to look for..... we are working on a budget but as you have said this will be essential if we hope to make the full journey trouble free.

Thanks for all the advice folks!

Gareth

Post by **toomanytoys** » 19 Feb 2007, 17:46

I am working in Havant and if I can be of any help I will, but I am travelling north and home at week ends, so maybe only as a courier sevice!!!
Or if you are in France and have a problem, or even want to stop off on the way..

Post by **www.charitytour.co.uk** » 19 Feb 2007, 19:21

Thanks for the offer.... I'll give you a shout if I'm struggling!

I have been busy looking up the process of converting to the DG engine..... I must say i'm still quite tempted to give it a go! I've always been a sucker for a bit of a challenge!!!

There's a seller on ebay who's 10miles down the road from me..... he's breaking 2 campers (both DG's) and I'm hopeful that I might be able to purchase everything I'd need from them (including a good engine and box).

If anyone could supply a full list of exactly what I'd need then that would be fantastic.

I know the general concensus is to go for the Aircooled CU rather than the DG and do value all of your opinions..... unfortunately all my experience with Aircooled has so far been bad!! Other than the obvious advantage in the ease of changing, what other advantages are there to the Aircooled over the watercooled? Is there much difference in fuel consumption and most importantly which of these engines is best suited to the T25? Please convince me one way or the other!

Has anyone here tried this before and got any good / bad stories??

Thanks again,

Gareth

Post by **matt** » 20 Feb 2007, 12:56

a well driven Aircooled 2.0 will keep up with an averagly driven 1.9 all day long
(well driven as in reading the road, correct use of 3rd gear etc)
there's only 8 hp in it

however, a poorly running, oil burning/leaking Aircooled with poor compression will go bang very quick, as you 3 found out on saturday......

no engine is bullet proof, but 3.5 litres of oil has too work hard for its cash

but a good fettled engine, this is not an issue

me dads done 22,000 in his with out a spanner being turned, cept to drop the oil

rather than spending time fitting radiators and electrics, get a 2.0 cu and spend the time geting it re sealed and the compression even, paying esp attention to the inlet manifolds, as any leak will make it run hotter

mpg, a well driven Aircooled will give 20 =22mpg, dg, about 22-25mpg

dont buy anything umless the seller come recommended, or you can drive the engine under load, IMHO

Post by **www.charitytour.co.uk** » 22 Feb 2007, 18:42

OK..... I'm now convinced that 2L Aircooled is the way to go.

Hence forth I'm looking for a good condition CU engine with tinware, exhaust, heat exchangers, etc..... basically complete (preferably with gear box).

I know George up in Scotland has one available available but the distance from me is a little too far, I'll travel as far as the midlands to collect but anything further may be a problem.

Please contact me if anyone has what I'm looking for!

Many thanks,

Gareth

Post by **matt** » 22 Feb 2007, 18:47

Dunna forget Carbs