instantsquid
New Member
- Posts
- 1,362
- Location
- Tadley, Hants
After much reading of the numerous conversion threads on here I hired an engine hoist and set about my 1988 Ninety last weekend. It took me the best part of the first day just to get the old 2.5TD engine out - I was convinced I had all the bell-housing nuts off, but had missed the one above the clutch slave cylinder.
Day two - I swapped over various bits from the TD to the TDi, including the flywheel housing, the wiring loom, and the oil filter housing. I fitted a new rear crankshaft seal, and a new clutch. I'd already fitted a new timing belt. I degreased the engine bay and painted over any bare patches of chassis with Hammerite.
Day three - I started trying to get the TDi into the Landy. It took me ages! I really struggled to get everything lined up - I was convinced I must have got the clutch off-centre at one point, so I took the engine out and re-centred the clutch plate. Take two and after lots of jiggling the engine slid into place. I left the engine mounts off so I could lower the engine right down in order to get to all off the bell-housing nuts.
I cut down the radiator mounting brackets and welded them back on 30mm lower. I also cut off the lugs on the side of the radiator frame and welded them onto the top of the frame so that the original radiator brackets would still fit.
Day four - Working out how to connect all the various "systems". For the PAS, I used the TD low pressure pipe. For the high pressure pipe I used the majority of the TD pipe, with just the end section of the TDi pipe connected using a small compression fitting. I had bought the exhaust and intercooler kit off the chap on eBay - downpipe and top intercooler pipe were easy to fit, but the bottom intercooler pipe was an incredibly tight fit. As already said, I fitted the TD oil filter housing and oil pipes, so these connected up to the TDi radiator easy enough once the TD converters had been screwed in. Radiator pipes were from the TD - they're a little bit kinked at the moment so will probably be restricting flow - for the price, I think I'll get the Steve Parker hoses when funds allow, just to make things nice and tidy. I used the TDi fuel filter, but extended the hoses using flexible fuel pipe and small jubilee clips.
I topped up the oil, power steering fluid and coolant... only to find my second hand radiator was leaking.
Day five - I got a pattern radiator from Keith Gott. Filled up the coolant, and had a final check that everything was ready to go. Disconnected the stop solenoid and span the engine until I was sure that oil was nicely circulated. Then I reconnected the stop solenoid and turned the key... Success! The engine burst into life instantly. I let it get up to temperature - no leaks from anywhere.
I joined the exhaust downpipe to the rest of the TD exhaust using the connecting piece that came with the kit. I used the TDi air filter and made some little brackets to bolt it to the wing. A final check and I took the car out for it's first test drive!
Initial pick-up from tick-over is perfect. At low revs, the engine feels great. But I've obviously got a fuel/air/turbo issue somewhere as once the revs rise, the engine starts to lurch - it feels like I'm lifting my foot up and down on the accelerator. When stationary, the symptom doesn't persist - it only happens when the engine is under load.
I shall try and diagnose the problem this weekend - hopefully it'll be something silly, rather than something expensive!
Ian.
Day two - I swapped over various bits from the TD to the TDi, including the flywheel housing, the wiring loom, and the oil filter housing. I fitted a new rear crankshaft seal, and a new clutch. I'd already fitted a new timing belt. I degreased the engine bay and painted over any bare patches of chassis with Hammerite.
Day three - I started trying to get the TDi into the Landy. It took me ages! I really struggled to get everything lined up - I was convinced I must have got the clutch off-centre at one point, so I took the engine out and re-centred the clutch plate. Take two and after lots of jiggling the engine slid into place. I left the engine mounts off so I could lower the engine right down in order to get to all off the bell-housing nuts.
I cut down the radiator mounting brackets and welded them back on 30mm lower. I also cut off the lugs on the side of the radiator frame and welded them onto the top of the frame so that the original radiator brackets would still fit.
Day four - Working out how to connect all the various "systems". For the PAS, I used the TD low pressure pipe. For the high pressure pipe I used the majority of the TD pipe, with just the end section of the TDi pipe connected using a small compression fitting. I had bought the exhaust and intercooler kit off the chap on eBay - downpipe and top intercooler pipe were easy to fit, but the bottom intercooler pipe was an incredibly tight fit. As already said, I fitted the TD oil filter housing and oil pipes, so these connected up to the TDi radiator easy enough once the TD converters had been screwed in. Radiator pipes were from the TD - they're a little bit kinked at the moment so will probably be restricting flow - for the price, I think I'll get the Steve Parker hoses when funds allow, just to make things nice and tidy. I used the TDi fuel filter, but extended the hoses using flexible fuel pipe and small jubilee clips.
I topped up the oil, power steering fluid and coolant... only to find my second hand radiator was leaking.
Day five - I got a pattern radiator from Keith Gott. Filled up the coolant, and had a final check that everything was ready to go. Disconnected the stop solenoid and span the engine until I was sure that oil was nicely circulated. Then I reconnected the stop solenoid and turned the key... Success! The engine burst into life instantly. I let it get up to temperature - no leaks from anywhere.
I joined the exhaust downpipe to the rest of the TD exhaust using the connecting piece that came with the kit. I used the TDi air filter and made some little brackets to bolt it to the wing. A final check and I took the car out for it's first test drive!
Initial pick-up from tick-over is perfect. At low revs, the engine feels great. But I've obviously got a fuel/air/turbo issue somewhere as once the revs rise, the engine starts to lurch - it feels like I'm lifting my foot up and down on the accelerator. When stationary, the symptom doesn't persist - it only happens when the engine is under load.
I shall try and diagnose the problem this weekend - hopefully it'll be something silly, rather than something expensive!
Ian.
