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andymacdonald30
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Joined: 18 Jun 2008
Posts: 48
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 Posted: Wed Aug 13, 2008 10:25 am Post subject: How to fit the intercooler/what engine mounts |
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I have tried to fit a pug 1.9TDI engine into my T25 and I was hoping that the engine mounts that I have in there on the 1.9 n/a engine would fit
But bugger the turbo gets in the way
so I need to make some new engine mounts
Any one got a design for this that they can let me look at please
Also the intercooler sits too high for the engine hatch to close
I was thinking of moving the intercooler in front of the engine bay by the side of the gearbox
The problem with this is connecting the inlet manifold to the intercooler
How has this problem been overcome by others who have fitted this engine into their vans?
Can you buy extensions with the correct fittings on?
Or is it a case of finding a rubber hose big enough to do the job with
Can any one give me some clues?
Andy
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2002 T4 2.5 tdi
1987 T25 1.9 D |
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aussie_b
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Joined: 03 Aug 2008
Posts: 24
Location: Berkshire
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| Posted: Sun Nov 23, 2008 2:55 pm Post subject: What adapter plate did you use? |
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Hi, I've got a Pug TDI 2.1 that I'm intending to swap into my T25. I was wanting a Famous Phil adapter but he seems to have gone underground.
Can you tell me what you used to connect the engine and box ? I've had the engine for a long time now so am really keen to get it done.
Any info would be appreciated. 
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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 |
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andymacdonald30
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Joined: 18 Jun 2008
Posts: 48
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| Posted: Sun Nov 23, 2008 4:12 pm Post subject: Re: What adapter plate did you use? |
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| aussie_b wrote: | Hi, I've got a Pug TDI 2.1 that I'm intending to swap into my T25. I was wanting a Famous Phil adapter but he seems to have gone underground.
Can you tell me what you used to connect the engine and box ? I've had the engine for a long time now so am really keen to get it done.
Any info would be appreciated. |
Hi there aussie-b
Mine was done by the previous owner but it consists of a 4 mm bit of steel cut out round the gearbox bell housing
Then the motor was put up against it and holes drilled in line with the gearbox holes
Looking at the gearbox the hole bottom left and the hole top right have been used to have a bolt through both the motor and the gearbox
There are three bolts holding the adaptor plate onto the motor and the starter motor is attached from the motor side via the adaptor plate as well
Hope that kind of makes sense
Also the motor is at approx a 50 deg angle from the upright
Have a look at a previous posting with pics of the motor (under What sump on a pug)
The only thing that I would not be able to make with normal tools (not professional) Is the attachment between the pug drive shaft and the vw clutch plate this I think would have to be done by a workshop
Has any one heard from Famous Phil?
Is he ok?
Good luck
Andy
_________________
2002 T4 2.5 tdi
1987 T25 1.9 D |
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andymacdonald30
Initiate Jedi
Joined: 18 Jun 2008
Posts: 48
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| Posted: Sun Nov 23, 2008 9:07 pm Post subject: Re: What adapter plate did you use? |
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| andymacdonald30 wrote: | | aussie_b wrote: | Hi, I've got a Pug TDI 2.1 that I'm intending to swap into my T25. I was wanting a Famous Phil adapter but he seems to have gone underground.
Can you tell me what you used to connect the engine and box ? I've had the engine for a long time now so am really keen to get it done.
Any info would be appreciated. |
Hi there aussie-b
Mine was done by the previous owner but it consists of a 4 mm bit of steel cut out round the gearbox bell housing
Then the motor was put up against it and holes drilled in line with the gearbox holes
Looking at the gearbox the hole bottom left and the hole top right have been used to have a bolt through both the motor and the gearbox
There are three bolts holding the adaptor plate onto the motor and the starter motor is attached from the motor side via the adaptor plate as well
Hope that kind of makes sense
Also the motor is at approx a 50 deg angle from the upright
Have a look at a previous posting with pics of the motor (under What sump on a pug)
The only thing that I would not be able to make with normal tools (not professional) Is the attachment between the pug drive shaft and the vw clutch plate this I think would have to be done by a workshop
Has any one heard from Famous Phil?
Is he ok?
Good luck
Andy |
I have been sitting watching the TV and something was buzzing round in the back of my mind Ref this posting I put on earlier today
Why is there a VW clutch plate in my vehicle?
It has a Peugeot motor and a T25 d Gearbox with a spigot extension from the pug drive shaft to a Vw spline into a VW clutch plate
Why not just get the pug driveshaft extended and use a pug clutch plate
As far as I can remember they were the same diameter so why change?
Would the drive shaft still need to be lengthened as the adaptor plate pushes the motor and gearbox apart by approx 5 mm could this just be taken up by NOT pushing the spline as far through the clutch plate as you would normally do? I don’t know I didn’t look to closely as I just put it back together as it was
May be you could file off 5 mm from the front of the gearbox ?
Only a thought but it may work
We need one of the experts on this forum to have a say in it
God my head hurts with all this thinking
Andy
_________________
2002 T4 2.5 tdi
1987 T25 1.9 D |
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aussie_b
Force Sensitive
Joined: 03 Aug 2008
Posts: 24
Location: Berkshire
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| Posted: Mon Nov 24, 2008 12:30 pm Post subject: |
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Hi Andy,
I've been thinking about trying to make an adapter plate up myself, because you'd think it can't be rocket science !!! My main concern is making sure the engine/gearbox line up.
Currently I'm running a 2.8I Ford V6 coupled to 5pd VW box, the adapter plate is approx 50-60mm wide (it looks like a section of large diameter pipe with some lugs welded on in the appropriate places). It uses a standard Ford clutch plate with an extended engineered drive shaft to fit Ford/VW. The clever thing is (seemed clever to me anyway), is that in order to compensate for such a wide adapter they've also made up an extension piece that slides over the drive shaft to marry up both the clutch plate and the throw out bearing...
Lots of things to think about, maybe I should just give a go - after all what's the worst that can happen? 
Thanks for the thoughts.
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 |
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andymacdonald30
Initiate Jedi
Joined: 18 Jun 2008
Posts: 48
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| Posted: Wed Nov 26, 2008 11:24 am Post subject: engine conversions |
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Ref to one of my last posts
I.E the drive shaft from the pug motor
I was obviously talking pants 
Got my self totally confused 
I mean the gearbox drive shaft not the motors 
There is and extension bit that slides over the gearbox shaft
This takes up the extra bit of length req due to the adaptor plate
But what was going through my mind at the time (no just the alcohol) 
As the adaptor plate on my conversion is only 5 or so mm thick
Would the shaft from the gearbox be long enough to not need the extension piece?
I don’t know and I do not remember looking into it when I had the motor out
But I do know one thing having the extension bit makes lining up the clutch plate very easy 
There is another thing to look into
The petrol and diesel fuel tanks are different not sure by how much but I do know that the diesel will req a return from the pump back to the tank
I have read about others who have tried this and I think the advice given was to get a new diesel tank fitted 
And fit a filter unit with an integral manual priming pump fitted to it
I think mine is from a zantia
I also run a fuel catalyst from www.broquet.com 
I DO get an added 10% mpg by using it
Andy
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2002 T4 2.5 tdi
1987 T25 1.9 D |
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