Pug 2.1 Conversion Questions

[aussie_b]

Hi, I've been doing (on and off) an engine swap from a 2.8 Capri over to a Pug 2.1 which I started about a year ago!!! The engine is in but now I need to do the fuel, plumbing and electrics and and have a couple of questions.

Fuel system - I'm using the in-line fuel pump that was used when the Capri engine was fitted. My question is, does anyone think this will cause problems or should it be ok?
Plumbing - trying to work out the flow of water, which pipe goes to where? Long pipe from radiator to water pump side of engine or other side ?
Electrics - ??? Not to sure what goes where, does anyone have an idiots guide to wiring the conversion?

Any assistance woud be greatly appreciated..
_________________
T25 Hi-Top Camper part way through conversion from 2.8I Capri Engine to 1.9 Citroen - longest conversion in history!!!
Merc 190d running on Veggie Oil - now sold

[famous phil]

Hi , would it be possible to take a pick of the 2.1 engine so can work out which type you have ?

There should be no need for the capri pump -it'll disrupt pump timing ,

engine hot water pipe should be the one closest drivers side - once running check that the hot water flows to the top of radiator ,

Electrics are strait forward , coil wire turns on fuel pump and heater-plug relay , an early temp sensor could be used drill and tap a Peugeot stat temp sensor bung ( some have these as three positions on stat housing depending on year ) M10x1mm .
oil pressure switch should be above oil filter ,

Hope this helps
_________________
Auto Union Munga Jeep ,T4 2.4td , T4 2.5tdi ,Mercedes S Class on LPG , 66 splity deluxe , GP mk1, 3 type 25s 1 with 1.9dt pug engine + 1 with N/A pug engine ,,there are 6 t25s with pug power in Darlington

[aussie_b]

Hi Phil,
Thanks for the info - I will take a couple of pics and post them shortly.

Just to confirm about the flow of coolant through the engine, are you saying the cooled water enters the engine at the water pump (passanger side), flows through the engine and heated water exits the engine the other side (drivers side)?

Cheers
_________________
T25 Hi-Top Camper part way through conversion from 2.8I Capri Engine to 1.9 Citroen - longest conversion in history!!!
Merc 190d running on Veggie Oil - now sold

[famous phil]

Thats normally what happens on the 1.9's but the 2.1's are different will check up on a pals today , these have the stat at the waterpump instead of at the top of cylinder head ,
early 2.1's are fitted with a top stat housing the same as a 1.9 but with no stat -
_________________
Auto Union Munga Jeep ,T4 2.4td , T4 2.5tdi ,Mercedes S Class on LPG , 66 splity deluxe , GP mk1, 3 type 25s 1 with 1.9dt pug engine + 1 with N/A pug engine ,,there are 6 t25s with pug power in Darlington

[aussie_b]

Hi Phil,
Please see photos of engine below;
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Not a great picture but hope it helps.
Cheers
Brett
_________________
T25 Hi-Top Camper part way through conversion from 2.8I Capri Engine to 1.9 Citroen - longest conversion in history!!!
Merc 190d running on Veggie Oil - now sold

[aussie_b]

This conversion will be the death of me !!!

After ages af no work being done, I got all gee'd up to crack on to finish it. Only to find that the clutch pedal wont budge which makes me think I must have put the engine/clutch/box together incorrectly...

Does anyone have any thoughts or better still is there anyone in or near Berkshire that coud help ?
_________________
T25 Hi-Top Camper part way through conversion from 2.8I Capri Engine to 1.9 Citroen - longest conversion in history!!!
Merc 190d running on Veggie Oil - now sold

[famous phil]

hi , my pal should be coming round with his 2.1 tomorrow so should be able to check flow , hot water has to leave engine at the top ( it would be wrong not too ) I've seen T25's with engine conversion and having been piped up wrong , a quick way to correct this is to swap the rubber hoses at the front of the long plastic cooling pipes


clutch slave push rod may need extending 6 to 8mm it might be at the end of its travel , try pushing the release arm back up and watch as someone presses the clutch
_________________
Auto Union Munga Jeep ,T4 2.4td , T4 2.5tdi ,Mercedes S Class on LPG , 66 splity deluxe , GP mk1, 3 type 25s 1 with 1.9dt pug engine + 1 with N/A pug engine ,,there are 6 t25s with pug power in Darlington

[aussie_b]

Thanks Phil, whilst I was underneath I was able to push the pushrod back up into the slave quite away and after reading your reply I realised that it probably was at the end of it's reach.

If I measure the slave push rod in the 'in' position and measure again once when the clutch pedal has been pressed, the difference should be the ammount the push rod needs to be extended. I guess this should be somewhere between 6-8mm as you suggest?

I haven't done the water pipe work as yet, so grateful to see which way the flow goes from your mates 2.1.

Thanks again.
_________________
T25 Hi-Top Camper part way through conversion from 2.8I Capri Engine to 1.9 Citroen - longest conversion in history!!!
Merc 190d running on Veggie Oil - now sold

[aussie_b]

A couple more questions...

Below is a picture of the IP, any ideas what each of the circled pipes are?
1 Fuel in, 1 Fuel return and 1 mystery (and which one is which? )



Any assistance appreciated.
Cheers
_________________
T25 Hi-Top Camper part way through conversion from 2.8I Capri Engine to 1.9 Citroen - longest conversion in history!!!
Merc 190d running on Veggie Oil - now sold

[famous phil]

highest pipe is from inlet = boost pressure ,

pipe at rear if this goes down near to fuel shut-off solenoid with a smaller pipe T'd into it this will be fuel return .

left tall oval = fuel feed in , sensor behind above oil filter/cooler is for oil pressure

one of the water pipes on the oil cooler will go up-to the hot water outlet - is the other loose = it will go to the expansion bottle

I see the pump has hot water pipes going to a device for adjusting the pump timing when cold , are these connected to the engine ?

on the pump behind the throttle damper there should be a number 0 460 ??? ??? could you see what it reads could do with the pump info as a pal is after that type for his

I'm just on sorting cooling pics
_________________
Auto Union Munga Jeep ,T4 2.4td , T4 2.5tdi ,Mercedes S Class on LPG , 66 splity deluxe , GP mk1, 3 type 25s 1 with 1.9dt pug engine + 1 with N/A pug engine ,,there are 6 t25s with pug power in Darlington

[ElusiveStranger]

[famous phil]