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72panelvan
Jedi Master
Joined: 17 May 2006
Posts: 297
Location: Dorset/Bristol
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 Posted: Tue May 13, 2008 7:05 pm Post subject: |
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there's no specialist tools, but it is a tad fiddly. It's a case of removing the bell housing, and then removing a cir clip on the far end of the input shaft. A geared collar (the reverse gear) then slides off and over the input shaft (i bent the end of an old screw driver to act as a puller as space is at a premium). The input shaft will then unscrew.
Personally, even if I was cutting it, I would remove it to ensure you can do it properly and then finish it off neatly. but if your going to the effort you may as well fit a 1600 input shaft! |
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13 window deluxe
Jedi Guardian
Joined: 22 Dec 2006
Posts: 861
Location: chesterfield derbyshire
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| Posted: Tue May 13, 2008 7:42 pm Post subject: |
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all 1500cc upwards inline 4 cylinder watercooled vw engines are the same (except pdi tdi) on the crank nose and rear of the block so what would be the point of kep supplying a water cooled adaptor plate that didnt fit any water cooled engines? the length of the input shaft is relative to the adaptor plate thickness my plate is 25mm and i didnt have to cut the shaft at all!. swapping the input shaft is a 1/2 hour job and the only tools you need is a pair of external circlip pliers and a 13mm socket and extention and a new gasket for refitting the bell housing
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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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trev
Jedi Master
Joined: 02 Feb 2006
Posts: 311
Location: Ireland
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| Posted: Tue May 13, 2008 8:41 pm Post subject: |
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| 72panelvan wrote: | | but if your going to the effort you may as well fit a 1600 input shaft! |
so the 1600 bay window input shaft is shorter then? By how much?
That would be ideal, a bolt-on replacement and still keep my original input shaft for down the line. |
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richbaker78
Teacher of Padawans
Joined: 31 Jan 2006
Posts: 1298
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| Posted: Tue May 13, 2008 9:05 pm Post subject: |
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| its 10mm longer than the 1600. |
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trev
Jedi Master
Joined: 02 Feb 2006
Posts: 311
Location: Ireland
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| Posted: Tue May 13, 2008 9:54 pm Post subject: |
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sounds ideal. KEP say half an inch (~12mm) 1600 input shaft is 10mm shorter, wouldn't be the end of the world to file 2mm off one.
Nice one  |
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jp
Darth Admin
Joined: 09 Nov 2005
Posts: 1984
Location: Chippenham, Wiltshire
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trev
Jedi Master
Joined: 02 Feb 2006
Posts: 311
Location: Ireland
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| Posted: Wed May 14, 2008 12:04 am Post subject: |
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cheers!
don't suppose you've got next week's lotto numbers? ;D |
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Bugsy_malone 666
Jedi Master
Joined: 19 Mar 2008
Posts: 394
Location: Near the Hells mouth known as Basingstoke
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| Posted: Fri May 16, 2008 10:26 pm Post subject: |
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I find it odd that they sell an adaptor kit yet the input shaft will still be too long!
I'm doing a 1.6 diesel golf engine at the moment into my bay using the T25 diesel bell housing onto a bay gearbox and the input shaft seems to stick out the same amounts on the stock bay gearbox with the diesel bell housing as when it was on the diesel gearbox.
Now working with that the enging I have was originally from a caddy, but im sure you can buy the spiggot bearing and have no problems, might be easier using T25 stuff to some extent as like you I am keen to keep my options so that should I choose to go back to the old engine its just a case of unbolting a few bits then sticking the old engine back in.
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Second Gear All The Way Baby!
Doing Thing Differently. |
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trev
Jedi Master
Joined: 02 Feb 2006
Posts: 311
Location: Ireland
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| Posted: Sat May 17, 2008 6:03 pm Post subject: |
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| 13 window deluxe wrote: | | passat 1.8 injection is same engine as gti pb engine code |
after much looking today I found the engine code under the grime on the block. It's an AAM code engine, 75 BHP, Bosch mono-motronic engine management, single point injection.
Doing a bit of research, there's a 90 BHP version of this engine, "ABS" engine code. Anyone know what makes it higher powered? It's the same capacity so is it higher compression? different cam? different fuel map/different ECU?
If it was something bolt-on like an ECU or cam I'd be up for swapping in the high-po bits after I've done the conversion.
I've located a shorter transmission input shaft too so I'll pick that up before embarking on the conversion. |
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Bugsy_malone 666
Jedi Master
Joined: 19 Mar 2008
Posts: 394
Location: Near the Hells mouth known as Basingstoke
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| Posted: Sat May 17, 2008 8:09 pm Post subject: |
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| trev wrote: | | 13 window deluxe wrote: | | passat 1.8 injection is same engine as gti pb engine code |
after much looking today I found the engine code under the grime on the block. It's an AAM code engine, 75 BHP, Bosch mono-motronic engine management, single point injection.
Doing a bit of research, there's a 90 BHP version of this engine, "ABS" engine code. Anyone know what makes it higher powered? It's the same capacity so is it higher compression? different cam? different fuel map/different ECU?
If it was something bolt-on like an ECU or cam I'd be up for swapping in the high-po bits after I've done the conversion.
I've located a shorter transmission input shaft too so I'll pick that up before embarking on the conversion. |
its the same as the mk3 golf engine range ( which is what my daily is) according to the haynes the compression ratio of the 75bhp version is 9:1 and the 90bhp its 10:1, the combustion chamber pressure is 77bar on the 75bhp and 7.5bar on the 90bhp so I'm guessing that increased compression along with a little tweek to the ECU is where 15bhp more comes from. it would appear it also has a different cam, each of the engines in the 1.8 range seems to have a different cam.
I think its probably a combination of things.
Still 75bhp is 25bhp over the stock 1600 engine in a bay!
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Second Gear All The Way Baby!
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trev
Jedi Master
Joined: 02 Feb 2006
Posts: 311
Location: Ireland
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| Posted: Sat May 17, 2008 11:15 pm Post subject: |
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| yeah but I'm upgrading from an 1800 type 4 engine. Not sure what the stock output is of the type 4 motor but it has to be about 70ish at least. I suppose even if I don't get any extra power from the passat engine I should get better economy than the 18-20 MPG I get at the moment... |
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Bugsy_malone 666
Jedi Master
Joined: 19 Mar 2008
Posts: 394
Location: Near the Hells mouth known as Basingstoke
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| Posted: Sat May 17, 2008 11:26 pm Post subject: |
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well 75bhp is a bit on the lazy side for the 1.8, as you say the abs is 90bhp and i think the mk2 1.8 multipoint injection lump was about 112-118bhp, sometihng like that.
obviously the normal rules apply you could get a performance header and airfilter aftermarket cams or maybe try getting one out of the abs engine.
my 90bhp golf reliably does 35mpg on runs and i drive it hard if i take it steady I can get that upto 37-8mpg, now im guessing your 1800 type4 probably did about 25-29ish?
then also you can plum in a much more effiecent heating system!
theres overall benefits in the long run against trying to maintain a type 4 engine with worn solex carbs.
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Doing Thing Differently. |
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