Page viewing: Engine change

Engine Preperation

Checked valve clearances, a couple of the inlet valves had virtually no clearance, a couple of the exhaust valves were also tight, took the shims to an engineering shop and got them ground down as this is cheaper than buying new shims. Fitted new timing belt, much easier with the engine out of the car :-) Fitted new water pump Adjusted injection pump timing (2 degrees advanced), marked up crank pulley with new timing marks:               Removed white ring from fuel pump compensator, hammered flat the dimple as well.                             Checked glow plugs (looked ok).

Engine Change

Engine change from 1.5TD to 1.7TD should be pretty straight forward, I expected the following: 1. Use the 1.5TD flywheel/clutch (fitted new clutch). 2. Turbo outlet points in different direct on 1.7TD, rotate the housing to the same location as the 1.5TD.        3. Inlet manifold different, use the 1.5TD. There was a couple of things that I had not expected and did not discover until I was fitting the engine :-( 4. Bracket that bolts to the bottom of the injection pump sticks out further on the 1.7TD.        5. The engine block has a slightly different casting, there is a lug by the starter motor on the 1.7TD that is not present on the 1.5TD, this stopped the engine from fitting as the lug hit the gear linkage, took a while to realise as the block casting being different was the last thing I expected.        6. The coolant pipe outlets on the thermostate housing are different, had to swop the housings over. 7. The 1.7TD engine mount is different (3 bolt fitting) and in a different location to the 1.5TD, this is a pain as the mount on the 1.5TD goes through the timing belt tensioner wheel and the 1.7TD one fits around the tensioner wheel, the tensioner's are a different design because of this. Its not just a matter of swopping the tensioners over as the backing plate and timing cover is different and one of the tensioner mounting holes on the 1.7TD is a larger diameter thread so the corresponding 1.5TD tensioner hole needs to be drilled out.        One other point that slowed up the engine change: 8. Although its possible to rotate the turbo housing due to the actuator/wastegate location the outlet from the turbo was not quiet in the same location as the 1.5TD, it points slightly forward compared to the 1.5TD turbo, this meant I had to cut and modify the pipe between the turbo and inlet manifold to get it to fit, I intend to fit an intercooler at some point so the pipework will need changing again but at the minute I just want to get the engine in and running. Also the inlet pipe on the turbo is a bigger diameter than the 1.5TD turbo so you need the flexible hose from the 1.7TD. Engine ready to go back in:

Other

While the engine was out I took the opportunity to do another quick couple of things: 1. Took the slack out of the gearchange by replacing the pin in the selector 'U' joint on the top of the gearbox with a nylock nut and bolt, the bracket has to be drilled out to allow the bolt to be fitted but well worth doing as the pin wears and is the main culprit in making the gearchange sloppy. 2. As I had fitted a new clutch I also fitted a new clutch cable, the combination of these two parts has made the clutch pedal very light. 3. Fitted a new radiator, when I had the old rad off looking into the inlet/outlet pipes I could see the core was thick with chalky deposits, this will restrict the flow (had this problem on my old corsa) which causes the engine to overheat when under load, decided it was worth replacing while the engine was out.