Joined: 19 Mar 2008 Posts: 394 Location: Near the Hells mouth known as Basingstoke
Posted: Mon Jul 21, 2008 10:18 pm Post subject: Back from Bugjam 760+miles covered!
Right well my conversions has worked!
so I took a bay, stuck a 1.6 diesel in to get better MPG, I did!
I hate filling up with diesel though, its so messy!
I managed to add sides to my scoop and that worked much better, after a 30 mile run including a large hill up and down it bled any air out the system and the engine ran sweet. doing 55mph the temp stayed at 80-85c.
Had a few minor issues with my particular engine itself but not with the conversion as such. I have some rattley hydraulic tappets which still seem to rattle a bit after almost 800 miles, have a small fuel leak from a breather on the fuel tank but that just needs a fresh bit of hose. I think im gonna change my exhaust too as long haul its a bit loud!
So whats the results?
Thursday morning I set off to pick up my g/f from my house to hers the other side of manchester.
Stage 2 - Manchester to Pod
Distance - Approx 165miles + upto 1hr running the engine at the pod charging the batteries etc
MPG - 32mpg (24litres) including the 1hr running at the pod.
Stage 3 - Pod back to Manchester
Distance - Approx 163 miles
MPG - Aprrox 33-34mpg (not good but it all seemed up hill)
Home Stage - Manchester back to my house
Distance - approx224 Miles
MPG - havent filled it up again but the needle is the same as the first trip/all stages which is arround 22-24 litres of fuel meaning approx 40+MPG
I cant see that having some extra on board with a big rucksack would knock 10MPG off but i think it could be to do with the style of driving. On the way down to pod we got stuck in traffic for about 20-30 minutes with the engine always running so that used extra fuel and on the way back from pod i dont get why i was doing such bad MPG.
I have 2 lots of fans on my cooling system 2 yamaha R6 fans on the front golf 1300 rad and 1 x 12-14" peugeot 205 GTi fan on the rear golf 1300 rad, I have some lights in the dash that come on when the fans do and in 760+miles of driving I had the R6 fans come on 3 times, twice when stuck in traffic for 20-30 minutes on the way away from manchester to sheffield and then once on the M1 on this hill which seemed to be about 5 miles long, brought the temp upto 95-100c, but fans only came on for a minute then went off again when we reached the top and it started to cool down quickly enough back to 80-85c.
The whole journey was taken at 55mph.
Improvements I think I want to make are Turbo Diesel and a different exhaust! I'm tempted now the cooling system is in to go golf 1.8 GTi, however getting the bus to do on average 37mpg is whats making me want to keep diesel - at the moment. I'm thinking if i could get a GTi lump to happily do 35-37mpg though doing like 55mph would be better as petrol is slightly cheaper and the GTi engine would seriously make it move above 65 happily (as the fuel economy falls off lol) 1.9 TDi is where I want to go.
Something else I have been thinking about is cooling system, Idealy I want to downsize and increase ground clearance, so far its been fine on my huge journey and accross santapod, but i want to change the engine bay so I have a single radiator mounted in there, people say its a bad idea but i want an engine driven fan like the normal air cooled petrol lump, forklifts manage, buses manage and they are all heavy load vehicles. I was thinking I either need a passat engine with viscous fan(and maybe a low profile kenlowe electric on the other side of the rad to assist if needed) or I was actually thinking of using the stock camper alternator/fan setup, which obviously will drink more fuel as its perminantly running but it could then be rigged so that the cooling worked like it did originally drawing the air through stock intakes and blowing down on the cooling area and the hot air going out under the back.
Still need to finish my heating too, one advantage of having rads under the floor is at night after a long run to santapod you have underfloor heating
lets hope what I have found here helps/inspires others who are starting a conversion _________________ Second Gear All The Way Baby!
Joined: 22 Dec 2006 Posts: 861 Location: chesterfield derbyshire
Posted: Mon Jul 21, 2008 10:45 pm Post subject:
glad everything worked out in the end a turbo would quieten the exhaust and give you a little extra torque but you might loose a couple of mpg but it would be worth it! i would even think about a gti motor in a van with fuel prices as they are now my t25 did about 20mpg with digifant gti engine and 40 mpg with 1.9tdi same van & same gearbox, if your going to swap the motor go for a 1.9 td aaz engine will treble your torque and double your horse power and will go straight in your van now the 1.6d's there you will just need to change the turbo oil return pipe (last one i did cost £10 for bits) _________________ 1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,
previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi
are you sure the engine has hydraulic tappets? I thought they were normal tappets on them.
I have just done an AAZ conversion in a t25 - have to say im not hugely impressed with performance but then Im used to driving a more modern 2.3l D. 75 bhp from a turbod 1.9 is pretty poor!!! but apprently there are lots of tweaks you can do to em.
Anyway - i am just about to ebay all my left over bits...I have one JX engine(1.6 TD) which is beyond repair due to knackered block...but it does mean I have all the conversion bits for an AAZ conversion - ie wedge sump with oil return, turbo and manifold (turbo condition unknown - suspect its kackered) inlet manifold, oil pick up, and engine mounts. rather sell the lot than bits. Can post (all but the block)but its heavy stuff. I also have a 1.9 TD block but i cant make out the engine code and think the HG might have gone on it (never had it running - just going on what I was told)
Joined: 19 Mar 2008 Posts: 394 Location: Near the Hells mouth known as Basingstoke
Posted: Tue Jul 22, 2008 12:41 pm Post subject:
richbaker78 wrote:
nice one - glad its all worked out.
are you sure the engine has hydraulic tappets? I thought they were normal tappets on them.
I have just done an AAZ conversion in a t25 - have to say im not hugely impressed with performance but then Im used to driving a more modern 2.3l D. 75 bhp from a turbod 1.9 is pretty poor!!! but apprently there are lots of tweaks you can do to em.
Anyway - i am just about to ebay all my left over bits...I have one JX engine(1.6 TD) which is beyond repair due to knackered block...but it does mean I have all the conversion bits for an AAZ conversion - ie wedge sump with oil return, turbo and manifold (turbo condition unknown - suspect its kackered) inlet manifold, oil pick up, and engine mounts. rather sell the lot than bits. Can post (all but the block)but its heavy stuff. I also have a 1.9 TD block but i cant make out the engine code and think the HG might have gone on it (never had it running - just going on what I was told)
hmm i just assumed it had hydraulic tappets, its a CR engine from an 82/83 caddy apparently, i thought vw made all thee engines with hydraulic tappets after they started making the T25 engines with them? not really that clued up on engines of that era. Guess I`ll have to have a look just incase, what should the clearances be?
as for your bits, first question is where are you, 2nd question how much?
you say the HG might of gone, whats the HG? maybe my mind is not with me today. _________________ Second Gear All The Way Baby!
well I know the JX engine 1.6 turbo doesnt have hydraulic tappets and i imagine they are all derived form the same engine. As for the clearances im not sure im afriad - i dont even have a manual for mine.
1st answer: melksham near bath
2nd answer: £125 for the lot....if you take the conversion bits then you can have the 1.9 TD (and JX) for nothing as i cant guarantee its condition - i cant see the code on it but probably AAZ - theres a derv pump with it but not on it. its down to a block/head basically no anciliaries but there is a whole host of other bits which came off the aaz and spare JX including alternators etc. i never ran it but the mate I got it off did and he said it started but smoked blue/grey...looking at the state of the turbo i wouldnt be surprised if that was the culprit however i assumed the worst as Rings or head gasket (HG)...frankly i couldnt be arsed with it as I had another easier option...there could be nothing wrong with it at all as said amte wasnt reknowned for his mechanical knowledge!!!
Posted: Tue Jul 29, 2008 1:38 pm Post subject: Re: Back from Bugjam 760+miles covered!
Bugsy_malone 666 wrote:
Right well my conversions has worked!
so I took a bay, stuck a 1.6 diesel in to get better MPG, I did!
I hate filling up with diesel though, its so messy!
I managed to add sides to my scoop and that worked much better, after a 30 mile run including a large hill up and down it bled any air out the system and the engine ran sweet. doing 55mph the temp stayed at 80-85c.
Had a few minor issues with my particular engine itself but not with the conversion as such. I have some rattley hydraulic tappets which still seem to rattle a bit after almost 800 miles, have a small fuel leak from a breather on the fuel tank but that just needs a fresh bit of hose. I think im gonna change my exhaust too as long haul its a bit loud!
So whats the results?
Thursday morning I set off to pick up my g/f from my house to hers the other side of manchester.
Stage 2 - Manchester to Pod
Distance - Approx 165miles + upto 1hr running the engine at the pod charging the batteries etc
MPG - 32mpg (24litres) including the 1hr running at the pod.
Stage 3 - Pod back to Manchester
Distance - Approx 163 miles
MPG - Aprrox 33-34mpg (not good but it all seemed up hill)
Home Stage - Manchester back to my house
Distance - approx224 Miles
MPG - havent filled it up again but the needle is the same as the first trip/all stages which is arround 22-24 litres of fuel meaning approx 40+MPG
I cant see that having some extra on board with a big rucksack would knock 10MPG off but i think it could be to do with the style of driving. On the way down to pod we got stuck in traffic for about 20-30 minutes with the engine always running so that used extra fuel and on the way back from pod i dont get why i was doing such bad MPG.
I have 2 lots of fans on my cooling system 2 yamaha R6 fans on the front golf 1300 rad and 1 x 12-14" peugeot 205 GTi fan on the rear golf 1300 rad, I have some lights in the dash that come on when the fans do and in 760+miles of driving I had the R6 fans come on 3 times, twice when stuck in traffic for 20-30 minutes on the way away from manchester to sheffield and then once on the M1 on this hill which seemed to be about 5 miles long, brought the temp upto 95-100c, but fans only came on for a minute then went off again when we reached the top and it started to cool down quickly enough back to 80-85c.
The whole journey was taken at 55mph.
Improvements I think I want to make are Turbo Diesel and a different exhaust! I'm tempted now the cooling system is in to go golf 1.8 GTi, however getting the bus to do on average 37mpg is whats making me want to keep diesel - at the moment. I'm thinking if i could get a GTi lump to happily do 35-37mpg though doing like 55mph would be better as petrol is slightly cheaper and the GTi engine would seriously make it move above 65 happily (as the fuel economy falls off lol) 1.9 TDi is where I want to go.
Something else I have been thinking about is cooling system, Idealy I want to downsize and increase ground clearance, so far its been fine on my huge journey and accross santapod, but i want to change the engine bay so I have a single radiator mounted in there, people say its a bad idea but i want an engine driven fan like the normal air cooled petrol lump, forklifts manage, buses manage and they are all heavy load vehicles. I was thinking I either need a passat engine with viscous fan(and maybe a low profile kenlowe electric on the other side of the rad to assist if needed) or I was actually thinking of using the stock camper alternator/fan setup, which obviously will drink more fuel as its perminantly running but it could then be rigged so that the cooling worked like it did originally drawing the air through stock intakes and blowing down on the cooling area and the hot air going out under the back.
Still need to finish my heating too, one advantage of having rads under the floor is at night after a long run to santapod you have underfloor heating
lets hope what I have found here helps/inspires others who are starting a conversion
your rattling tappet noise may be a bad injector they can make an awfull racket if there not spraying properly , run the engine then slack each injector pipe in turn and listen for the rattle , if it disapears then swap injector to another cylinder and do the test again . if the noise moves with the injector then replace it.
also this may give you bad or variable fuel consumption.
ive just comleted my round trip to bugjam via devon, linconshire , north yorkshire and wales , 1180 miles and 148 litres of diesel
mostly at 65 - 70 mph doing an average of 37MPG.
and my van is very heavy 2.2 tonnes unladen at a guess loaded for 2 weeks closer to 2.6 tonnes so you should get at least the same mpg or better with your van..
dave.. _________________ 1969 bay with vw 1.6td
Joined: 22 Dec 2006 Posts: 861 Location: chesterfield derbyshire
Posted: Fri Aug 01, 2008 8:39 am Post subject:
hydraulic tappets came in at about 85ish in the early mk2 golf but they never fitted them to the jx (might be due to extreme engine angle? just a guess)if i remember correctly they were manual shim adjustment till the end of production in 92. caddy sounds right about the injectors having a poor pattern try that first it will cost nothing _________________ 1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,
previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi
Joined: 19 Mar 2008 Posts: 394 Location: Near the Hells mouth known as Basingstoke
Posted: Fri Aug 01, 2008 9:18 am Post subject:
hmm I'll have to have a look then, would also probably explain its slightly poor starting!
is it something I can treat with injector cleaner at all or is a new injector job?
at the moment im rather tempted by richbakers engines for rebuild as a 1.9td would go nice in the camper and i could rebuild and check everything over, then know my engine was good for another 3 billion miles.
however currently after doing the engine conversion and bugjam funds are a little short as I need to fit a new windscreen to my golf and do some paint work to it keeping the camper running to use as a daily for a few weeks. _________________ Second Gear All The Way Baby!
Joined: 22 Dec 2006 Posts: 861 Location: chesterfield derbyshire
Posted: Fri Aug 01, 2008 6:03 pm Post subject:
try a bit of injector cleaner in the tank in it for what it cost's if that doesnt cure it then try cracking of the injectors off one at a time like caddy said and once you find the duff one try it in another cylinder to see if the missfire goes with it? if it moves the 1.6 injectors are cheap new from gsf if not it's a compression loss problem some where for how long it takes wip the rocker cover off and check the valve clearances see if there all close might give you a idea where to start looking if 7 are set ok and 1 is a yard out you can bet thats the pot with the miss, but start with the fuel injectors P.S. sometimes the injectors are a bit seized in to the head get some wd40 or diesel round the threads at the bottom the day before and take them out when the engine is stinking hot they move easier and dont forget the sealing washers on the bottom of the injector dont have 2 on a injector and none on the next _________________ 1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,
previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi
Joined: 22 Dec 2006 Posts: 861 Location: chesterfield derbyshire
Posted: Fri Aug 01, 2008 6:10 pm Post subject:
the difference between a 1.6 and a 1.6 td is big when it's on boost puling a van along, but the 1.9td is streets ahead of the 1.6td as the crankshaft is mega long (does give a little more vibration at idle) the torque comes in much lower on the 1900 engines the 1.9tdi (1z-ahu etc) give max torque at 1900rpm! and the 1.9td(aaz) is 2400rpm where the 1.6 are up in the 4000rpm ish area make the van much nicer/easier to drive when you dont have to change up and down the box all the time _________________ 1964 rat 13 window deluxe 1Z tdi,
1975 rhd twin slider tintop (TBA)
1991 golf 2 gti with tweaked AHU tdi,
previous tdi swaps: gone but not forgotten
1979 rhd twin slider tintop bay ahu 1.9tdi
1990 T25 1Z 1.9tdi
1993 suzuki samurai with 1Z 1.9tdi
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but you might loose a couple of mpg but it would be worth it! i would even think about a gti motor in a van with fuel prices as they are now my t25 did about 20mpg with digifant gti engine and 40 mpg with 1.9tdi same van & same gearbox, if your going to swap the motor go for a 1.9 td aaz engine will treble your torque and double your horse power and will go straight in your van now the 1.6d's there you will just need to change the turbo oil return pipe (last one i did cost £10 for bits)
for how long it takes wip the rocker cover off and check the valve clearances see if there all close might give you a idea where to start looking if 7 are set ok and 1 is a yard out you can bet thats the pot with the miss, but start with the fuel injectors P.S. sometimes the injectors are a bit seized in to the head get some wd40 or diesel round the threads at the bottom the day before and take them out when the engine is stinking hot they move easier and dont forget the sealing washers on the bottom of the injector dont have 2 on a injector and none on the next
