A quick guide to fitting an 1.9 AHU to a t3 transporter

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A quick guide to fitting an 1.9 AHU to a t3 transporter

ViestiKirjoittaja 1961nuffield » 30.09.2017 17:15

A quick guide to an 1.9 mtdi installation in a t3 2wd transporter.

Back in December of last year I swapped a running car for a sick transporter with a jx engine in it.
Although I got the jx engine running it was pretty sick and the turbo was worn. This is my 5th transporter and I’ve always felt a little more power was needed!

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While looking on tori.fi I spotted a seat 1,9turbo engine for a reasonable 60€, a quick trip to Jyväskylä with the trailer and one very oily tdi was mine. It was missing the flywheel and the turbo side of the induction was apart but included.

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My plan was to get the engine running on a test rig and then install it in the van, as to this point the engine was an unknown quantity. The oil leak was from a cracked breather!

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Initially I set the engine up with a 1.6 non turbo flywheel and clutch plate, and the jx pump, I still had the AHU sump and oil pump fitted. I used the AHU injection pipes, with the ones for cylinders 1 and 2 rerouted a little. The jx bracket had to be cut away and reworked so that the pipework fitted.

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The timing was set by guestimation and was found to be 18 degrees BTDC when I checked it. At this point the turbo wasn’t fitted, and the oil feed blanked off. The engine ran quite well, didn’t smoke so I decided to continue.I then fitted a jx sump and a 1.6 non turbo oil pump, which I knew to be good.
I blanked the filler off at the bottom of the sump, as I’ve never been keen on the system.

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I changed the crank seals at this point and fitted the spigot bearing to the end of the crank, to support the gearbox shaft. I also used the jx water pump, alternator bracket, and changed the crank pulley to one that used a v belt.

I checked the two jx tubo’s I had and both looked wet with oil when I ran them, so a friend offered me a fiat ducato turbo for 30€ It was a warranty return and apparently whistled!!

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I made a test plate to check the turbo would physically fit when using the jx manifold and then made a permanent plate up to mount the turbo up in the correct position.

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The turbo fitted in well, I had to make up the oil fittings for the feed and return, I used the tapped hole in the jx sump and a custom made converter.

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The exhaust came next and was fabricated in the style of the jx but with a slightly bigger bore, it uses the original mounting points and style.


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The engine was ready for fitting and installation, which went well. I ran the engine for a while like this, but retimed it to 15 degrees BTDC which improved the torque and performance.

I also fitted an intercooler on the advice of another forum member.

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The vehicle was now ready for re registration, which as you all know isn’t without its issues, but after asking for advice and a lengthy chat at my local kats station I went ahead. I’d checked the emissions beforehand at a friends work place, but for the “muuttokatsastus” they had to be done again on site. The crucial point at the kats was that they had on file a piece of paper from VW Finland which stated that the brakes and suspension was identical for all T3 transporters from 1983 onwards. I was also installing a stock engine with no power upgrades. I had to provide a bill of sale from when I bought the engine, and pay 125€ as well!

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Since then I’ve traveled just over 9000km and the van is running well, I swapped the clutch early on in the process to the best one I had in my hoard, and I haven’t had a problem with it slipping. The replacement had springs with a large coil diameter.
I’ve also reinforced the air inlet side as it was collapsing when warm under high revs.

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One useful gadget I bought was a converter from Gunston which allows you to fasten a clamp to the injection pipe of number 1 cylinder and then use a normal strobe to check the timing, a bit expensive but very easy to use.

Good luck and I hope that this quick guide is of use, sorry that it’s in English but my Finnish is not so good.

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Viimeksi muokannut 1961nuffield päivämäärä 08.10.2017 14:22, muokattu yhteensä 1 kerran
1961nuffield
Vasta alkaja
 
Viestit: 2
Liittynyt: 22.06.2017 20:09
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Re: A quick guide to fitting an AHU to a t3 transporter

ViestiKirjoittaja Caravellix » 30.09.2017 20:42

Thanks mate, I´m sure that it´s useful to someone and it´s always nice to read about successful engine swaps.
We have our annual T3 meeting at the Espoon automuseo at 7.10., you´re welcome there to show your wheels in live.


Cheers
Design is not simply art, it is elegance of function. - Ferdinand Alexander ´Butzi´ Porsche
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Caravellix
AktiVWisti
 
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Re: A quick guide to fitting an AHU to a t3 transporter

ViestiKirjoittaja 1961nuffield » 01.10.2017 15:53

Caravellix kirjoitti:Thanks mate, I´m sure that it´s useful to someone and it´s always nice to read about successful engine swaps.
We have our annual T3 meeting at the Espoon automuseo at 7.10., you´re welcome there to show your wheels in live.


Cheers


Thanks I think I will be there, I missed it last year!

John
1961nuffield
Vasta alkaja
 
Viestit: 2
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Re: A quick guide to fitting an AHU to a t3 transporter

ViestiKirjoittaja Pastori » 01.10.2017 22:08

Very nice write up, always pleasure to read something like this :)
Datsunisti ja tölökkinisti.
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Pastori
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Re: A quick guide to fitting an AHU to a t3 transporter

ViestiKirjoittaja Wolkkariman » 06.10.2017 10:17

Thank^s for information of engine swap " Petrol Head ", if i can say so :mrgreen:
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Wolkkariman
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