IMG 2562 volkswagen t3 van life littlewagen

Swaping engine to 1.9TD (AAZ) – Part 2

keefirivunts

An engine swap is never an easy process, it takes a lot of time and money. If you plan to get on the road quickly and cheaply, then buy a van that already has a swapped/rebuilt engine. We went the hard way and here is our engine swap story, part 2.

 

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We will be documenting all our build details in Instagram Story Highlights @littlewagen and will be posting more about the build here.

 

For Part 1. – Click here

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Messed up the oil pressure sensor thread. So pulled the head from the engine and… – Click here for more + how I fixed it.

So after fixing the thread and fitting new BMW (wroom wroom) oil pressure sensor it was time to pull out the old engine.

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First I needed to mark the wiring and fuel lines. Eventually I changed most of the lines and wiring but it was still good to know where something is supposed to go.

vw t3 t25 engine strip swap 1.6td jx 1.9td aaz

You can see the timelaps of our engine pull on our Instagram under “Engine” story highlights.

vw t3 t25 engine strip swap 1.6td jx 1.9td aaz

vw t3 t25 engine strip swap 1.6td jx 1.9td aaz

vw t3 t25 engine strip swap 1.6td jx 1.9td aaz

So after pulling the engine I started to disassemble everything and it started to get interesting! 😅

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Engine sump was full of bits and pieces. 

vw t3 t25 engine strip swap 1.6td jx 1.9td aaz

It had snapped the connecting rod that managed to hit through the engine block. Not really sure what happened in here but luckily I only needed a sump and the oil pump.

volkswagen vw t3 t25 engine jx 1.6td 1.9td aaz swap

vw t3 t25 engine strip swap 1.6td jx 1.9td aaz

Cleaned everything up and installed the JX oil pump and oil dipstick tube.

vw t3 t25 engine strip swap 1.6td jx 1.9td aaz

And then installed the sump and oil feed pipe from the JX. Alternator from the AAZ and the water tubing from JX.

vw t3 t25 engine strip swap 1.6td jx 1.9td aaz

Also used both JX waterhousings for the cylinder head cause the AAZ plastic housings have newer connectors and the old aluminium ones feel much better. 😎

volkswagen vw t3 t25 engine jx 1.6td 1.9td aaz swap

Cause the old engine had a huge oil leak, and I think the last owner drove it like that, the engine was full of oily dirt so it took a lot of time and brake cleaner to clean it up. And yeah the van drove on 3 cylinders pretty well and didn’t sound that bad.

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Unfortunately my phone and computer(where I had all photo copies) died at the same time and I don’t have any content of finishing the engine build nor the engine-body marriage.

BUT luckily I posted almost everything on Instagram Stories! + turbo clocking and engine marriage.

I think you have to be logged in on Instagram to see those but here is the link that takes you to the enginge highlight. – CLICK THIS BADA** LINK

If you have any questions then write to the comments and I’ll try to answer them as soon as possible.

Bodywork nightmare!! – Coming soon!

 

JX to AAZ swap TO-DO listClick here

Shopping list

  • Upper gasket kit 
  • Cylinder head gasket
  • Cylinder head bolt set
  • Glow plugs
  • Seal rings
  • Crankshaft oil seal rear
  • Oil sump gasket
  • Thermostat
  • Timing set (belt + pulley)

Thank YOU!! for reading and hope you like what you see. We will be documenting all our build details in Instagram Story Highlights @littlewagen and will be posting more about the build here.

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