Sivu 1/1

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

Lähetetty: 30.09.2017 17:15
Kirjoittaja 1961nuffield
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!
1485022890197.jpg
1485022890197.jpg (36.67 KiB) Katsottu 3326 kertaa

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.
IMG_20170305_171250.jpg
IMG_20170305_171250.jpg (893.2 KiB) Katsottu 3300 kertaa
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!
IMG_20170316_143406-1.jpg
IMG_20170316_143406-1.jpg (1.08 MiB) Katsottu 3300 kertaa

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.
IMG_20170319_103922.jpg
IMG_20170319_103922.jpg (975.01 KiB) Katsottu 3300 kertaa

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.
IMG_20170919_094328.jpg
IMG_20170919_094328.jpg (1.41 MiB) Katsottu 3299 kertaa
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!!
1490104267976.jpg
1490104267976.jpg (40.29 KiB) Katsottu 3299 kertaa

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.
IMG_20170322_132543.jpg
IMG_20170322_132543.jpg (953.33 KiB) Katsottu 3299 kertaa
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.
IMG_20170321_225213.jpg
IMG_20170321_225213.jpg (861.45 KiB) Katsottu 3299 kertaa
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.

IMG_20170328_130424.jpg
IMG_20170328_130424.jpg (814.25 KiB) Katsottu 3299 kertaa

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.
IMG_20170620_122107.jpg
IMG_20170620_122107.jpg (952.78 KiB) Katsottu 3299 kertaa
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!
IMG_20170622_104120.jpg
IMG_20170622_104120.jpg (832.47 KiB) Katsottu 3299 kertaa
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.
IMG_20170919_094337.jpg
IMG_20170919_094337.jpg (1.52 MiB) Katsottu 3299 kertaa

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.
IMG_20170614_105141.jpg
IMG_20170614_105141.jpg (1.24 MiB) Katsottu 3299 kertaa

Re: A quick guide to fitting an AHU to a t3 transporter

Lähetetty: 30.09.2017 20:42
Kirjoittaja Caravellix
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

Re: A quick guide to fitting an AHU to a t3 transporter

Lähetetty: 01.10.2017 15:53
Kirjoittaja 1961nuffield
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

Re: A quick guide to fitting an AHU to a t3 transporter

Lähetetty: 01.10.2017 22:08
Kirjoittaja Pastori
Very nice write up, always pleasure to read something like this :)

Re: A quick guide to fitting an AHU to a t3 transporter

Lähetetty: 06.10.2017 10:17
Kirjoittaja Wolkkariman
Thank^s for information of engine swap " Petrol Head ", if i can say so :mrgreen: