1.6d Woes!

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Iceworx
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1.6d Woes!

Post by Iceworx »

Morning all

Just wondering if anyone could offer me some broad advice please.

I have recently aquired a 1.6d '89 T25 hightop.

Its hard work selecting gears, and 1st is very very very slow and moving off from standing.

I have done a little reading, and im considering an engine swap :) although I dont know what all the engine codes are, I have done swaps on other cars before now.

First of all, does it sound like a dying gearbox, or is that the norm for the 1.6d?

I've seen serveral people upgrade to 1.9 Na and TD engines, is there a huge advantage to having the TD ?

also lastly, since im doing the engine swap, is there a straightforward engine/gearbox combo that will prettu much drop straight in?

Thank you in advance
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Post by camper »

1.9 1Y engine easy conversion & more torque.

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Post by Iceworx »

What vehicles will I find a 1Y in please?

IS this a straight forward swap with the bearbox as well?
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Post by camper »

I fitted a 1Y 1.9n engine as a replacement for the worn 1.6td in my van.The engine came out of a caddy van but golfs or seats have them.If you can get a good AAZ 1.9td engine which are from a golf or seats thats an other alternative .You would need a 1.6td sump and other bits to convert from 1.6n to TD there is lots of information on the forums about it.If you fit a 1Y 1.9n its a straight swop over using the 1.6n sump& inlet+exhaust manifolds and the flywheel&clutch.I was lucky enough to get a low mileage engine 70.000 fron a caddy from a local scrappy. I sold off the 1.6td parts and this paid for the 1Y 1.9 engine.

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Post by Iceworx »

Did you use the same gearbox? or the gearbox off the 1Y ?
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Post by HarryMann »

Is this a straight-forward swap with the bearbox as well?

We don't tend to get involved with advice on them here... :)

I am unsure if you mean you think the box is starting to pack up or if it's just the change selection mechanism..

Very often the selectors get worn, or lose their adjustment, there is a 'lot' of info in the Wiki on this, so read all this stuff first and see if it makes sense, then get back here with any further questions... its a complicated system of levers and pivots and joints.

I expect it is that causing the problems changing gear, although at least check that the box itself is not leaking oil at the joints between the castings... if there's any sign at all, then check the oil level in the box asap, even change it just for peace of mind (about 4 litres I think). The magnetic drain plug will give you a good idea of the condition, by what sort of fir-tree you find on it, or any larger pieces that might come out.. keep them as evidence!

As advice above, the 1.9 ND (1Y) is an easier conversion, the TD requires more work, has more to go wrong and when installed they produce more heat and often benefit from an oi cooler up-front, which isn't exactly cheap. They both fit fairly easily though onto your current gearbox, but both require a slight increase in gearing, best obtained by simply increasing wheel size to 15" with suitable Aspect Ratio tyres that give a 5~10% larger rolling circumference.

Once converted, you can then judge whether you really need a different gearbox, but it's really the TDi conversions that need much higher gears, not necessarily the NA and TD IDI engines.

I would though, put a completely new clucth in at point of conversion, clean and degrease the flywheel surface well, and use a new spigot bearing, also checking that the clutch arm and its bearing in the bell-housing are in good condition and not stiff as well as grinding any burrs off the operating fork ends, to give a nice smooth clutch action and assist gearchanges.

PS. If possible, try to hear the donor engine running, preferably see it start from cold too! If it has maintained well with regular air, oil and fuel filter changes and oil changes, they should last at least 150k miles.

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Post by Iceworx »

Thanks harry.

To clarify, its not selecting a gear that an issue, its actually moveing in 1st..

Even with laods of revs its got nothing to it at all...
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Post by HarryMann »

Still not quite clear?

What happens in 2nd and 3rd then? and 4th?

Are you saying something's changed or it has just got a very low 1st gear (which of course it does have)...

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Post by Iceworx »

2nd 3rd and 4th, and 5th all seem to be ok..


But 1st is a nightmare to move off in..
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Post by HarryMann »

The drift I'm getting is that it's too low for normal use..

So why use it unless you are heavily loaded and pointing up hill? Or is it the change from 1st to 2nd that's a problem, that you've almost stopped before you engage 2nd?

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Post by camper »

Iceworx wrote:Did you use the same gearbox? or the gearbox off the 1Y ?
.The gearbox fitted to the 1Y engine is from a 2ltr cu Aircooled T25 DK code my choice but requires linkage and extra work .As adviced its not neccesary best to fit 15" wheels.

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Post by Iceworx »

Im still trying to figure out if its a problem with the gearbox, or the engine being underpowered etc..

Havent tried setting off in 2nd yet..
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Post by camper »

Your 1.6n could be worn or has issues.As having owned several 1.6n T25s and fitted with petrol gearboxes i never had any problems with first gear .

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Post by Iceworx »

Sounds like it could be the box then...

Think I will drop the oil and go run a magnet through it :)
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Post by Aidan »

No need to run a magnet through it there's one on the drain plug will tell you all you need to know, send me a piccy if you want a diagnoses, but it may well be collapsed first gear and end case bearings, it's the weakness with the five speed I'm afraid.

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