1.6 to 1Y this weekend

Post by **greenman** » 10 Apr 2008, 18:07

So i have to change my 1.6 this weekend as it know spills out so much smoke you cant see behind you.

Not done this befor so it should be fun.
Have read all the old posts i can find and dose not seem to bad.
just need to know if the exh will fit ok and what mod do you have to do the the fule pump. sol and accel cable.

Thanks for any help
shore i will post some more probs over the weekend and will take some photos to .

Adrian

Post by **camper** » 10 Apr 2008, 18:17

Inlet&exhaust manifold will fit .There is a black plastic box on the 1Y fuel pump.Break it off carefully and underneath is the fuel cut solonoid connect your black ignition wire on it.I used the 1.6 td throttle cable&attached plate to screw on the bosch pump.Bent down the the 1Y damper plate which has a slot in it for the telescopic .Used that to connect the throttle cable to .

Post by **andysimpson** » 10 Apr 2008, 18:20

camper wrote:Inlet&exhaust manifold will fit .There is a black plastic box on the 1Y fuel pump.Break it off carefully and underneath is the fuel cut solonoid connect your black ignition wire on it.I used the 1.6 td throttle cable&attached plate to screw on the bosch pump.Bent down the the 1Y damper plate which has a slot in it for the telescopic .Used that to connect the throttle cable to .

inlet manifold will fit but not properly

Post by **camper** » 10 Apr 2008, 18:28

Stand corrected yes it will fit but not properly .Both bolt on okay but the shape&size of the 1Y ports are diffrent to the 1.6n

Post by **greenman** » 11 Apr 2008, 06:00

Thanks for that will it be better to use the 1Y inlet ?

Also do i use my old fly wheel, cluch and bell housing ?

Thanks againg a big help

Post by **camper** » 11 Apr 2008, 06:50

Greenman within the last 4 weeks i worked on a replacement 1Y engine for the worn 1.6td i had.I took my time on it replaced the crankshaft rear&front oil seals cambelt& tensioner + bottom pulley&bolt .If you read up on the discussion forums you will see 1Y topics that cover this.Regarding the exhaust&inlet manifold you can still use your 1.6n manifolds and pipe to silencer.This is how some other 1Y conversions are done .The only problem is the inlet ports and size dont match up not exactly and small losses in efficiancy occur.With regard to my own set up i used the 1Y exhaust manifold and fabricated the 1.6td down pipe to bolt and to fit the 1.6td silencer.I then used a 1.6n inlet manifold & airbox .The 1Y engine runs very well returning good MPG & fair speed.But as Andy simpson said its not a proper set up with the inlet manifold.It is possible to remove some of the inlet manifold metal to reshape it to the 1Y port size.But reading up on the forums this can leave not much metal around it after removal to the right size.Regarding using the 1Y inlet manifold its such a tight fit it interferes with the engine compartment side to it.For it to fit you will have to make clearance on that side.Flywheel clutch to bellhousing from the 1.6n used.Oh dont forget to install the spigot bearing this fits inside the crank end.

Post by **greenman** » 11 Apr 2008, 07:04

Thanks for that Camper.should be all the Qs cleared up.
Pick up the engine tonight after work so should do a few hours on it tonight be for it is dark.
Going to fit a new cluch and cam belt thats why i need to know be for i try fitting it which cluch to get.
Have been looking at the old posts thats where i got a lot of info from has been a big help.

Thanks every one

Adrian

Post by **ringo** » 11 Apr 2008, 17:11

Just spent the first day changing my engine - all is going well.

Just swapping the bits over from the 1Y to the new 1Y - its a lengthy process and im just taking my time.

I have decided to keep the original dipstick in - i wont be able to check the oil level without opening the boot - but the dipstick on it is such a good fit and mine existing one is rubbish.

Apart from that, nothing to report.

Good luck tomorrow

Ringo

Post by **kit** » 11 Apr 2008, 18:23

what is the spigot bearing?

Post by **greenman** » 11 Apr 2008, 19:01

well started to take the old engine out after work and got it all ready to drop tomorrow when i get a engine lift.
the new 1Y is all apart with a new cambelt readt to go on tomorow as well.

think it should be done by the end of the day

I am looking at leaving the old dipstick in as well.

Post by **greenman** » 11 Apr 2008, 19:03

kit wrote:what is the spigot bearing?

it is the little bearing in side the flywheel.

Post by **kit** » 12 Apr 2008, 10:19

greenman wrote:
kit wrote:what is the spigot bearing?

it is the little bearing in side the flywheel.

Thanks can I get one at GSF ? If so I will add it too my ever growing list.

Post by **greenman** » 12 Apr 2008, 18:15

Yes they are £5 ish i think.

Post by **greenman** » 14 Apr 2008, 15:18

Well it dose not go I need help

The engine starts but will only rev to 2 g and is running realy ruff on any thing but idle.

Have tryed every thing timming etc.

Any one got a clue?

Post by **camper** » 14 Apr 2008, 16:47

When you say checked the timing.You are at T.D.C at the pointer at the V mark bell housing.injection pump locked up with the pin & cam lobes no 1 cylinder 10 oclock & 2 oclock with camshaft locking plate in the slot.Throttle adjustment has to be set if the injection pump lever has been taken off the peg.I had a problem initially with my 1Y due to not getting enough revs i reset it on the spline on the pump throttle peg.