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1.6CS to AEF Engine Swap

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colinthefox View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote colinthefox Quote  Post ReplyReply Direct Link To This Post Posted: 17 May 16 at 22:06
Sorry, missed your post. I didn't get an email notification.

Yes it does sound like the timing is not right. Apart from recommending the usual checks I can't help you with that.

The pressurisation of the cooling system doesn't look good though. Could be cracked cylinder head or blown head gasket I suppose. You could get the coolant tested at a garage.

The commencement of injection solenoid should work as I described. Your problems could be due to the timing or connected to the cooling system problems.

To be honest I would suspect that your engine is bad, but can't be sure based on what you have said.

1.9D AEF T3 Kamper
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Daaf Quote  Post ReplyReply Direct Link To This Post Posted: 15 Jul 16 at 22:44
thank you for the reply.
a little update after some months of daily driving.
The problems with the pressurised cooling system is solved with a new pressure cap.
The engine is getting considerable warmer than the CS engine but I didn't have a boiling engine yet. I live in Spain though in a mountain area so I am always keeping an eye on the temperature gauge.
The bearings of the powersteering pump broke because lack of oil. I bought an other one that I could open and now I keep an eye on the level in the pump every 1000km.

I have a friend with a broken JX engine and I told her that the cheapest fix will be to replace it with an AEF. so maybe I will do a JX to AEF conversion soon.

Almost forgot to tell that I bought an other gearbox and now I am able to drive 110 km/hour and I use 8 liters for 100km.
Hope to read some more folow ups about the AEF.
Thank for the very useful information [:)]
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Post Options Post Options   Thanks (0) Thanks(0)   Quote colinthefox Quote  Post ReplyReply Direct Link To This Post Posted: 17 Jul 16 at 21:06
Daaf

Glad you got it sorted, and thank you for posting feedback. It really does help others.

We drove over the Picos twice last year, and really enjoyed the trip. Twelve years ago we did that with the CS engine and really struggled!

Colin
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Post Options Post Options   Thanks (0) Thanks(0)   Quote whizwest Quote  Post ReplyReply Direct Link To This Post Posted: 25 Aug 16 at 10:16
Hi Colin, some time ago you posted an excellent article about exchanging a 1.6 to the 1.9D AEF engine.
I have done the refit and it's running, but I have a problem.
It idle's ok on tickover , and then when you drive it, it accelerates ok, then went you take your foot
off the gas, it stalls.

your article talks about the high idle vacuum activator, and the air bleed screw?

Any advice?

Thanks Chris
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Post Options Post Options   Thanks (0) Thanks(0)   Quote colinthefox Quote  Post ReplyReply Direct Link To This Post Posted: 25 Aug 16 at 15:33
Chris.

Once the diesel system has been filled and the engine running, the air bleed screw does nothing.

The high idle device has very little effect on anything really. Just as it's name suggests, it varies the idle speed a bit, but shouldn't lead to stalling either way.

I don't really have any idea about your stalling problem, except to check that you don't have an air leak on the suction side of the pump, and that the idle screw hasn't been interfered with.

Good luck

Colin
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Post Options Post Options   Thanks (0) Thanks(0)   Quote fdb Quote  Post ReplyReply Direct Link To This Post Posted: 13 Sep 16 at 14:06
Hi looking for some help please. Fitted a aef engine from a skoda fabia 1.9.
Got her running but if I over rev she cuts out and the timings are then out so won't restart without putting the timings right, anyone got any help to offer please.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote colinthefox Quote  Post ReplyReply Direct Link To This Post Posted: 13 Sep 16 at 20:56
Sorry, once again I don't hve much clue as to what might be wrong, except to look at the fitting of the timing belt and in particular the tensioner. Is the belt running true?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote boatbuilder Quote  Post ReplyReply Direct Link To This Post Posted: 15 Jan 17 at 00:13
Thanks for the brilliant guide. I'm working through it at the moment so I may have some questions!
Does it cause any issues having the delay off switch operating even on an already hot engine?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote colinthefox Quote  Post ReplyReply Direct Link To This Post Posted: 15 Jan 17 at 21:40
Originally posted by boatbuilder boatbuilder wrote:


Does it cause any issues having the delay off switch operating even on an already hot engine?


Good question. No. It just advances the injection a bit, making it sound a bit more dieselly.

Best of luck with the conversion.
1.9D AEF T3 Kamper
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Post Options Post Options   Thanks (0) Thanks(0)   Quote boatbuilder Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jan 17 at 00:34
Thanks for that. Getting there slowly. Just removed the vanes from the power steering pump today...don't have any power steering fluid handy and would rather not have to buy a bottle to fill up the tiny pump. Do you think I could use any other kind of oil in there instead? I'm planning to plug the bottom outlet of the pump with jb weld and a coin and just plug the middle of the top outlet so it can still be unscrewed if needed.
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Post Options Post Options   Thanks (1) Thanks(1)   Quote colinthefox Quote  Post ReplyReply Direct Link To This Post Posted: 16 Jan 17 at 09:39
Engine oil is perfectly OK. Once you've removed the vanes it's just an idler wheel.
It's up to you how you blank off the ports, but I like to have a mechanical retention in addition to adhesive in case of failure.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Antzg Quote  Post ReplyReply Direct Link To This Post Posted: 20 Jan 17 at 11:30
What a fantastic guide! this has saved me so much time so many thanks for your hard work! I bought my van with the engine already removed so have a little dilemma. I just wondered if any of you lovely people could tell be which colour wires go to where? currently I have the following:

Black - ignition live for fuel stop solenoid
Blue/white - to heater plug temp switch
blue/black - to oil pressure switch on the head???
red - glow plug

I currently have the remaining:

black
yellow
yellow/red

Thanks you in advance :)
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Post Options Post Options   Thanks (0) Thanks(0)   Quote boatbuilder Quote  Post ReplyReply Direct Link To This Post Posted: 06 Feb 17 at 18:00
Lots of wiring questions at the minute!

The AEF alternator has three connections - not sure where to connect them all up:

B+    main heavy wire to + battery terminal
D+    blue wire to the dash charging led
W     not sure what this is for? - never mind, I've figured it out, its for a Rev counter if you have one.


Edited by boatbuilder - 08 Feb 17 at 09:35
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Post Options Post Options   Thanks (0) Thanks(0)   Quote boatbuilder Quote  Post ReplyReply Direct Link To This Post Posted: 09 Feb 17 at 09:01
Does the AEF suffer from the crank bolt problems like the AAZ does? Just wondering if I should undo the crank bolt and torque up a new one? Or just leave the old one untouched?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mrhutch Quote  Post ReplyReply Direct Link To This Post Posted: 09 Feb 17 at 14:30
not as much as the turbo but I often do change them anyway, especially if there doing a t-belt/waterpump anyway
T3 1981 Westy Vanagon - thinks lubricant is a fuel
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Post Options Post Options   Thanks (0) Thanks(0)   Quote boatbuilder Quote  Post ReplyReply Direct Link To This Post Posted: 10 Feb 17 at 17:46
So I've bought this little delay off relay. It's really tiny, not sure where to put it.
Can't make sense of the wiring on it. Can anyone help with what to connect up where ?





Edited by boatbuilder - 13 Feb 17 at 11:35
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Post Options Post Options   Thanks (0) Thanks(0)   Quote boatbuilder Quote  Post ReplyReply Direct Link To This Post Posted: 13 Feb 17 at 11:39


So I think I've figured it out...
 
It doesn't seem to be possible to wire this in with the starter wire because once the engine is started, the starter wire goes back to zero volts which makes the relay switch off instantly, which is obviously no good.
I'm going to connect it to the ignition wire instead.
The only issue I can see is that you'd have to make allowances for the length of glow time as the relay starts counting down from the second you turn on the ignition. So I'm guessing I'll probably set the relay for the maximum time of 40 seconds.
 


Edited by boatbuilder - 13 Feb 17 at 13:46
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Post Options Post Options   Thanks (0) Thanks(0)   Quote colinthefox Quote  Post ReplyReply Direct Link To This Post Posted: 22 Feb 17 at 13:17
Originally posted by boatbuilder boatbuilder wrote:

Does the AEF suffer from the crank bolt problems like the AAZ does? Just wondering if I should undo the crank bolt and torque up a new one? Or just leave the old one untouched?


Sorry, missed these last few, as I've been away for a couple of weeks in a place with no internet or mobile phone. Bliss! (No, not prison. We know they all have mobiles there!)

No. The AEF shouldn't suffer from the crank bolt problem, as the alternator should have a clutched pulley, and the belt won't be putting rotational stress on the crank pulley. If it's OK now I would leave it.

I think you've sussed out the relay wiring. It's actually not the relay I would have chosen, as doesn't have a separate trigger wire, but it will do OK the way you've got it.

It would be great to get feedback once you have it running.


1.9D AEF T3 Kamper
All sorts of other oil burners too.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote boatbuilder Quote  Post ReplyReply Direct Link To This Post Posted: 25 Feb 17 at 22:24
It seems to be working well. Not a hint of smoke at start up.
I've noticed that after the glow plug light goes out, the plug relay stays active for another few seconds and then you hear it clicking off. I presume this is something to do with the resistors on the glow plug wire. I had thought it would have been in sync with the light?

So far so good, looks like the gamble on the 100 quid engine paid off... I had to rebuild the alternator as it was very noisy and I'm chasing various coolant hose leaks and my gearbox or clutch is rattling at idle unless you press the clutch pedal....

The AEF itself is a lot more smooth than the old CS and as someone already said, you can generally go up hills in a gear higher than before. I'm thinking a sensible cruisng speed would be 55mph..... what does everyone else do?
Oh and I have no oil leaks! Proud of that one!

Edited by boatbuilder - 25 Feb 17 at 22:26
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Post Options Post Options   Thanks (0) Thanks(0)   Quote colinthefox Quote  Post ReplyReply Direct Link To This Post Posted: 25 Feb 17 at 23:37
Well done. I bet you were grinning from ear to ear by the time you got into third!

Originally posted by boatbuilder boatbuilder wrote:

I had thought it would have been in sync with the light?


I think it's designed for a bit of "Afterglow". Nothing to do with the resistor.

Well done for no leaks. I had no leaks initially, but have just had to pull the gearbox 20K miles on because the rear crank seal was leaking.

55mph is about right for cruising with the standard gearbox. You could always slip in a longer top gear set. I think they are 0.77. That would retain the hill climbing of 3 gears, with cruising at 60.

The clutch rattle is probably the drive springs on your clutch plate a bit loose. To diagnose that, if you let the clutch out veeeeeeery slowly in neutral, it probably won't do it. Not a problem.

Now grab yourself a 100 quid spare engine, to be sure.

Incidentally, my clutch plate that has done 20K miles still has the numbers printed on the wearing face. You can pull away at an idle in most situations.


1.9D AEF T3 Kamper
All sorts of other oil burners too.
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