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1.6CS to AEF Engine Swap

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roonster View Drop Down
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    Posted: 15 Jun 21 at 06:07
van past mot running fine then it all went shit !!!
Started to splutter and stutter s bit like lack of fuel ? Found a little leak so hopefully just that 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote colinthefox Quote  Post ReplyReply Direct Link To This Post Posted: 02 Mar 21 at 22:49
Originally posted by roonster roonster wrote:

colin you were correct the battery I have is rather big for the diesel won't fit under seat so will move it to enige Bay, only managed to get this fores up briefly other day after waiting nearly a year lol
It fire so that a bonus still need to sort out wiring and exhaust but slowly does it lol sounded good tho 
ANY pointers with wiring guys would be appreciated as I say petrol to iesel conversion 


Well done for getting it running. Clap Sorry, I can't help you any more with the wiring.
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 roonster Quote  Post ReplyReply Direct Link To This Post Posted: 02 Mar 21 at 17:03
colin you were correct the battery I have is rather big for the diesel won't fit under seat so will move it to enige Bay, only managed to get this fores up briefly other day after waiting nearly a year lol
It fire so that a bonus still need to sort out wiring and exhaust but slowly does it lol sounded good tho 
ANY pointers with wiring guys would be appreciated as I say petrol to iesel conversion 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote colinthefox Quote  Post ReplyReply Direct Link To This Post Posted: 20 Dec 20 at 21:09
...........Oh, and of course the battery will need to be bigger. Diesel batteries are normally in the engine compartment. If leaving the battery in the front of the van, the size of the main cable to the starter motor will have to be increased substantially, and I'm not sure you can get a diesel starter battery shallow enough to fit under the seat.
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 colinthefox Quote  Post ReplyReply Direct Link To This Post Posted: 20 Dec 20 at 20:15
Originally posted by roonster roonster wrote:

great write up this just installed an aef into our van but it's originally a petrol so I need to sort out wiring? Don't know if different 


There will be a load of differences between the old Petrol wiring and the AEF. You'll need glow plug wiring and relay, and a light on the dash. If you have a tacho, that will operate differently, taking its signal from the W terminal on the alternator, as does the buzzer of doom. I can't really help with that as I've never converted from petrol to diesel, but others have, and may be able to help.
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 roonster Quote  Post ReplyReply Direct Link To This Post Posted: 19 Dec 20 at 15:28
great write up this just installed an aef into our van but it's originally a petrol so I need to sort out wiring? Don't know if different 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mrhutch Quote  Post ReplyReply Direct Link To This Post Posted: 01 Apr 20 at 00:53
That’s easily done. Post a photo of what you have.
T3 1981 Westy Vanagon - thinks lubricant is a fuel
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Post Options Post Options   Thanks (0) Thanks(0)   Quote skipperdiego Quote  Post ReplyReply Direct Link To This Post Posted: 01 Apr 20 at 00:23
I think it has immobilizer on injection pump

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Post Options Post Options   Thanks (0) Thanks(0)   Quote mrhutch Quote  Post ReplyReply Direct Link To This Post Posted: 31 Mar 20 at 21:51
they are all non-ecu (kind of) some do have immob though
T3 1981 Westy Vanagon - thinks lubricant is a fuel
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Post Options Post Options   Thanks (0) Thanks(0)   Quote skipperdiego Quote  Post ReplyReply Direct Link To This Post Posted: 31 Mar 20 at 14:05
I'm waiting the AEF to arrive from the scrapeyard, I hope it's a no-ECU version
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Post Options Post Options   Thanks (0) Thanks(0)   Quote rowlesy Quote  Post ReplyReply Direct Link To This Post Posted: 31 Jul 17 at 10:46
oh yes made me tut i can tell you! i really thought it was main bearings or clutch problems....
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Post Options Post Options   Thanks (0) Thanks(0)   Quote colinthefox Quote  Post ReplyReply Direct Link To This Post Posted: 30 Jul 17 at 22:42
Oooh!

Lucky it didn't jam the oil pump pulley then. That would have been terminal!
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 rowlesy Quote  Post ReplyReply Direct Link To This Post Posted: 30 Jul 17 at 22:06
just thought i'd put this up here....
my aef's been in for possibly three months now and ive always had a rattle not long after fitting sometimes at tick over sometimes at full chat and sometimes all the time even with clutch depressed! i read somewhere that the newer engines vibrate a bit in the t3 because there now not harmonized  along with there old gearbox and engine mounts? i thought that was kindof bollox as ive put a fair few un-t3 engines in these buses! so i was having difficulty locating the noise i thought the worse and whipped off sump to check crank and con rods. all fine there..... so took of upper and lower cambelt covers off to have a mooch there. again looked fine but lots of metal filings? so a bit more messing turned up a spacer that had dropped down behind the oil pump pulley and was sat there rattling around! once i got that out i figured out where it had come from......to take the engine out the caddy (skoda) one of the engine mounts is just below the crankshaft pulley. when i took this off unbeknown to me theres a spacer that sits under that mount. it must of dropped out when i undid the bolts! so there you go just a heads up! i did think the engine was fucked hence taking the sump back off!
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always out numbered never out gunned!    RWS welding 07846 380 467 (worcs)
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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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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: 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: 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 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 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: 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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