1Y conversion.

[jacoldar]

Hi

This is a mad forum. I 'm learning loads . I want to give my 79 1600cc lawn mower bay a 1Y (Golf 1.9D - Mech pump) diesel upgrade. I had her in France last year and was robbed with petrol and couldn't relax much with the wondering when it was gonna blow.. Anyways, France booked again for this summer... heading to the Alpes.
Just a couple of questions thrown up from the research I've done on this so far. i'm trying to keep things as cheap as possible cause i'm skint right now..
1. Not pushed about speed or power even, just realibilty and economy which my 1Y engine should provide. Would it be ok to mate with my 3 rib gearbox in the bus. I'll put on bigger wheels/Tyres and would hope to upgrade gearbox for 2015 summer trips.
2. Is there great adifficulty to making your own adapter-doen't seem to be a popular choice seeing as they are 200 odd to buy.
3. Confused with the inout shaft, won't it be too short with adapter added. do it need extention welded on at the end or is it sorted using different flywheel/clutch arrangements.
4. Does the 1Y engine need to be mounted at some angle in the Bay- do I need different sump, oil pick up. I know I read this somewhere.

Thanks lads
I hope you can anwer some of these queries, I'm a little confused .

[trev]

if you've already been looking around then you'll have seen my thread: http://vwkd.com/bb/viewtopic.php?t=3962

I upgraded to the 2-litre "6-rib" gearbox and TBH, even with 205/80R14 tyres on the back, it's only comfortable to cruise at 50MPH. Any faster and it just gets too loud inside the van and the engine really sounds like it's being taxed a bit too much.

From what I've heard from mates with diesel converted bays and from reading around here, the upside-down B5 Passat 5-speed gearbox really is the way to go. One chap described the difference between the Passat box and the 6-rib bus box as "night versus day". See if you can budget for the 6-rib box at the very least. You'll be able to sell it on again after the trip to France. Then upgrade to Passat-spec.

Re the input shaft, it's quite long in stock configuration as the airc00led flywheel is quite deep and the needle bearing inside the gland nut is quite a way away. When you fit up the 1Y (and after you've fitted a needle bearing inside the 1Y crank nose you'll need to knock off 5mm from the input shaft. Mind you, that was using a KEP adapter plate. It really depends on what thickness of plate you use.

Don't forget the starter motor. You'll need a heavy-duty starter motor. KEP sell one for mega bucks, some people will report using bay window automatic transmission starters but those are only marginally more powerful than the standard petrol engine starter. I got a starter from a diesel B4 Passat and made an adapter plate.

Where do you plan on putting your radiator?

have a good read of my thread, I've jumped most of the hurdles and documented them there. It's reliable, never once over heated and pretty good on fuel (35MPG+ versus the 18MPG I was getting on petrol). I reckon with the Passat 5-speed it'll be even better and won't be so loud while cruising at a normal speed. Aside from upgrading the transmission, the last hurdle for me will be adding a heating system for the cabin. I have no heating at the moment.

Best of luck with the project and make sure to take lots of photos and post your progress here