tdi conversion

Beast o Bodmin · Apr 8, 2009

ok....

I have my engine sorted so the task begins.Ive sorted out alternator placeing and it will have the existing everrything i have only if the powersteering pump aint on the engine it will be the biggest headache so not so bad really.the cambelt is being done as we speak and clutch too seeing as its on the bench.Im gunna take me bonnet arf tomoz and start the dissassembly of V8 and gas system.ive yet to work out the way ofd emptying the gas tanks so tomorrow will be a gas quest i think.I have decided to take piccies as i go and then post them job lot.save minging up the camera and puta get Mrs BoB to snap at it

anyone got a trailer for sale 8ft as the one i use belongs at work and im going out on me own

Beast o Bodmin · Apr 9, 2009

Well today was er erm....

i started with the engine bay removed the secton from vapouriser to carbs and the carbs.There was a startling amount of gas in the line

I then removed the wireing system and the vapouriser again with **** loads of gas.
That was then put in to the work shop laid out in ordered sections.The tank removal and pipe work was next.Carefully removeing the filling pipe work in one piece and also the gas to engine pipe work in one piece part from the pipe runs front to back its intact.Two tank straps and one gas connection with a leak/bteather pipe and an in feed per tank each pipe system was also filled wiv gas.There is also some wireing too.
I found the filler cap easy.8 bolts makeing a clamp plastic fitting.It has left a large hole in the body that may be an option to route exhaust in the side wing but its by the filler cap so not sure.I did split the breather hose for the tank so a small job there but easy mistake to fix so far.Ive got so much room.2 door van here we go. The tank brackets were substantial and took the old mull grips to hold the nylocks while i was socket fittin it.It was also raining.anyway my shocks have now become a little more supple.

Tomorrow im going to tackle the radiator and alternator.Power steering exhaust and if time put the scaffold up

Oh when you pull the pipes out the bottom of the vapouriser stand back cos it ****is out coolant

all in a good day.

edit....
i rember now i had to take the carbs off to get the lpg fittings.i would of left the carbs on otherwise.

Beast o Bodmin · Apr 10, 2009

righto ...
started this morning by takeing piccies

ive decided to take a few snaps at the start of the day.its less hassle.
first today off with the bonnet clasp area and the front grill.
then i had to take the plastic fan cover off slide it back and the removed rad pipes .Un bolted two side mounts and lifted the radiator.then i took arf the fan on the water pump.the alternator followed and had such a long lead i popped it on the right hand wheel arch.it was on the left as you look at it.Rocker covers then the manifold and valley gasket.i then took out the long bolts holding the waterpump on.pulled that off with a bit of a tap.the exhaust got hacked and un bolted easy enough.the power steering pump came off to one side but took a bit of fiddleing as the bracket was awkwarsd.the ignition was held in with one bolt fork shaped bracket and the drive shaft just pulled out easy so i popped on the dizzy cap and lobbed it intact in the eletrics box.I then removed the sump oil and sump.
so now i can see the bell houseing bolts and the front is clear.
Scaffold tomoz and block n tackle job.Will get midday shots no doubt.

going well and i havent had to cut anything off yet.1 split knuckle so far.

gavbriggs · Apr 10, 2009

aye, its the big push on mine in morning, it will be in the workshop on the ramp though and i will be using o/head crane to get lump out then converting it to a v8 again but a running one this time!

Beast o Bodmin · Apr 11, 2009

gavbriggs said:
aye, its the big push on mine in morning, it will be in the workshop on the ramp though and i will be using o/head crane to get lump out

..no such luxury for me.
started today with some piccies and set about the bellhouseing bolts.I used a ring spanner and un did each i could reach.
I then cold formed the spanner into a special shape

continued to remove the rest of bell h bolts.i left the starter on cos it were gettin tired.this took me till 10.30.had some coffee and set up scaffold a frame,beefed it with some spurrs a few cross members some rope and hey presto a frame.I collecteed some chain and hook and used the engine strap holes attached to the head.
I then undid the engine mount rubber bolts on both sides.takeing the tension of the engine i jacked up the gear box and stuffed in a piece of wood between the crossmember and the box.
I the pulled up the engine and tapped out the front mount rubbers.

Lowered the engine and box back on to wood chock and gently raised han lowered the engine while jammin a chainsaw spanner in the gap to prise off the drive spline.
wiggle poke swear and hey presto arf come the v8.i lifted the engine to the top of the tripod and tied it to the side in front of the range.then lowering the engine in a swing motion onto the wheelbarrow.

lowered the chain and tackle off un hooked.
took a fewmore piccies and took down scaffolld.wheelbarrowed the V8 into the shed and dinners on.

so three days so far......engine and gas kit out.

gavbriggs · Apr 11, 2009

i did most of that but i had removed heads first and wiggled with ramp up n down and o/h crane thingy. it eventually came loose. i used a pry bar too but **** know where or how!

Beast o Bodmin · Apr 11, 2009

so then im going tdi gav so should be easy ish to refit eh.

Beast o Bodmin · Apr 12, 2009

ok..
day four has been spent cleaning the engine bay and every thing i can get at ready for waxoyling.the chassis is solid so i have wire brushed and jet washed that also.The baulk head is solid and the wheel the footwell repairs i did appear solid.I have gat all needed eletrics in condiuit and basically going to lag the lot in waxoyl while the engine is oot. Tomoz a small patch of inner wing fabrication required underneath the washer bottle and small patch at 12.00 on both sides jobs a gud un.
didnee bother takeing pics today as it looks the same as the end of yesterday bar the mud.
the suspensino is a good 3" up each end so far

Beast o Bodmin · Apr 14, 2009

day five...

well today has not quite gone to plan...
I have to change my bell houseing and the fact of this makes me have to re-plumb the clutch to totherside.Also me starter aint gunna fit.This is all just nuts and bolts so im takeing me bellhouseing tomoz to tdi engine and see which one fits....
There is plenty of choice

so as i see it its just the circuit to put in place for the glow plugs and the intercooler.Plenty of room....

It is alot of work however it will be top for me and it WILL be intercooled.If i have trouble wiv the match up then i may just go an wack a 5 speed box in.Im gunna try not too as me cousin built a strong box .....

so push on tomoz...

engine ready friday....

Sean · Apr 14, 2009

five days to do an engine change !

Beast o Bodmin · Apr 14, 2009

5 days yes but i aint fooked up nothing and not a rounded bolt yet..

also im gunna have the tdiest engine bay in the west ya lanky get

im gunna have to fit a snorkel too

Sean · Apr 14, 2009

Beast o Bodmin said:
im gunna have to fit a snorkel too

that'll add at least another week to the job at this rate

Beast o Bodmin · Apr 15, 2009

went to engine today to sort out bits.
the bell houseing wont fit so box out too.....
its gunna have to be 5 speed disco set up so ive also got to change holes for sticks hand brake......
anyway i got a nice looking inter cooler and me mate has got a pimp blue boyracer oil rad for me

ive got two clutches (1 new )so push on .ive made the brackets for the intercooler to go in the front behind the grill infront of the rad.This will help.good bit of HP there.im wondering where for the oil rad.i reckon some where safe so it dont get scat i suppose.
ive got to also swap the clutch over too.I think for future access im going to put a doorway in on the transfer tunnel like me series was as this will make box swap easy in future with the bolt on crossmember.

The engine comes with air con pump on so i was wondering what the pressure in the pipework is ?Could it run a hydraulic pump for a winch?

ive arranged pickup on friday of box and engine so ive just a few hours to get the box out......it does look heavy,i dont mind a Transit box but this one looks awesome....

Beast o Bodmin · Apr 15, 2009

and a few more..

Beast o Bodmin · Apr 23, 2009

ok.
day 7 was spent takeing the gearbox oot....

Fu Ckin ell That hurt...
a few days tree cutting and on to day 8 ..
I started with getting the gearbox "service"changeing oils cleaning and lubeing moveingparts.I serviced the handbrake drum and painted it.Got my head round where to put the handbrake as this is mounted on the box in the range.I slid it on its side and jacked up the range a bit.Rolled over the bax and then wiggled and pulled the box and transfer box up onto the crossmember it came with.I jacked the lot up into the chassis and went in side to see where the gear knobs fouled.Cut that with tha grinder.finished with the box on stands.Went to scrap yard and got air filter off ldv.I SEE A RANGE IN THE BACK>.......
4 hours later i get kicked oot £20 lite...
day 9
I have spent the day tidying up the wireing.Ive had to change the battery side so new earth points requiredAlso the power steering res has been moved toother side.I put some pipe tails on the heater so its easy later on...
I removed the clutch which is new and put the thing back with the bolts done right not like the mechanic at farm..Swapped the mounting for the clutch slave to otherside..Popped to another secret scrapper and got some engine mounts to fit...
put up the scAFFold and strapped a tarp on cos its gunna rain and i have the engine hoist on hire tomoz....
engine in tomorrow i hope but as ever stuff to do when in the hoist. part from the oil drain and filter change hopefully sorted so i can plumb it in this weekend.

wreckhunter · Apr 23, 2009

Are you using the standard tdi radiator/intercooler/oilcooler setup or making your own?

Beast o Bodmin · Apr 24, 2009

wreckhunter said:
Are you using the standard tdi radiator/intercooler/oilcooler setup or making your own?

Im useing my V8 rad....
Home fit oil rad and an intercooler from disco.I have decided to make each system seperate so i can have any water rad i want.In theroy i can use my running gear for all chassis...

wreckhunter · Apr 24, 2009

Was just wondering as I replaced my damaged radiator a few months back i noticed the oil cooler was part of the radiator and that the intercooler was next to it on a frame,seems a good setup but then i suppose i might not give you the options of other engines later.

Beast o Bodmin · Apr 26, 2009

wreckhunter said:
Was just wondering as I replaced my damaged radiator a few months back i noticed the oil cooler was part of the radiator and that the intercooler was next to it on a frame,seems a good setup but then i suppose i might not give you the options of other engines later.

im haveing my massive v8 rad with a jap oil cooler and twin intercoolers...

all seperate yes.that way i can use any water rad i like...

ok.this weekend went well......NOT

got my engine in but it dont fit so engine out.I have to change the air intake for the cabin as on the two door it is different and does foul the top of the rocker cover.I have noticed the RRC from which the tdi was fitted has much more room,also the starter motor is going to have to be "moulded into the footwell".... :doh:
i have also got some different banjos for the oil rad from the slittywagon and now i have metric to imperial pipework for the oil cooler.this job is quite extensive but seems logical looking at the manwell for dissassembley of the bit round the windscreen.No doubt there will be work to do in there too once i get in...
I think the change was made in 1985 for the baulkhead but not sure.anyway hack slash chop fir tree bashing this week so will cut the fook outta my baulkhead next week.

Beast o Bodmin · May 9, 2009

Well...
My engine is on its mounts.

Ive used 2.5 na engine mounts.This has raised the engine giveing me awesome sump clearance which is very pleasing.I have had to relive the pressure on the baulkhead

...I have cut the valley gutter out and am going to reroute the airintake for the cabin.I may go retro jap motor fit on heater matrix as they are small.

The rocker cover is tight but only the tops of the injector pipes hit the bonnett.The disco bonnett is higher and ive lifted the engine.I was going to cut the bonnett but decided to drill small holes and fit some screenwasherjet type caps tpo be discreet.I got a big ass intake arf slitty bit didnee like it.
The engine is now further back and higher giveing me room for twin intercoolers ,oil rad any water rad i feel so inclined to fit and also room for winch behind me grille

.
I have removed the extra lights on the grill as requested by some Ranger Rover offical and added some light impact protection

I have had to remove heater forr the mo as the gearbox has decided to take up some room.
I have cut out the tunnel and am going to replace with door like an old series for swift access.
I have removed the chassi cross member that originally fitted and am going to use the one ye disco box comes sat on......

More to come next week...

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