“If you want a hand lifting anything let me know, I’m happy to pop over and take the strain!”
….that’s how I found myself sliding under the back end of Grens Karmann Gipsy to assist refitting the gearbox. Gren has been working on an engine transplant, out comes the wheezy 1.6 lump and in its place goes a 1.9 SEAT Tdi, ideal for pushing the unaerodynamic caravan with a motor along at a sensible South of France cruising speeds with less of the slowing down when an incline appears on the horizon!
The hard work of dropping the drive train out, cleaning and fitting the ancillaries onto the new engine and refitting had been carried out, but the gearbox needed to be raised underneath and bolted home, not an easy task given its size and cumbersomeness in the confines of the underside of a Volkswagen T25. With the van up on ramps we began.
We slid the box under on a board and manhandled it onto the carefully positioned trolley jack, inching it under its final resting place the handle was slowly pumped, raising it upwards to the chassis, with much straining and fine adjustment with feet, knees and shoulders the splines aligned and the bolts on the front plate were spun home, we were almost there!
With a spacer inserted and the bolts torqued up correctly the gearbox was in.
Time to step back and admire another piece of the jigsaw that is an engine swap.
You can read more of the story behind this on Grens website and forum
Steve.
Oi you, less of the "Wheezy". The 1.6TD is a great little engine, but it lacks the grunt when it comes to hills and long inclines. Bird Lip Hill just isn't fun with the 1.6TD - even 32t lorries fully loaded overtook us, whilst we were in 2nd gear, doing 20 mph and looking worrying at the temperature gauge.
ReplyDeleteThe 1.9 TDi will push the Karmann uphill at 40-50mph because it has som emuch torque. Just the thing if you are visiting Austria and Switzerland.
Fingers crossed it'll all work.
Thanks for your help Steve! ;-)
No problem, happy to help. Be interesting to have a spin behind the wheel when its completed to feel the power!
ReplyDeleteThere is only 20 BHP difference between the JX and the 1Z, so not a lot of difference. What really makes the difference is the torque in the engine.
ReplyDeleteThe 1Z simply has tons of torque. As you may have read on the Karmann Coachbuilts forum, Mario (who has done a few conversions before) stated - "The TDi is so worth it. Finished off a AAZ conversion today and to be honest if feels no different to a JX to drive. You still have to rev it hard to make it go. Whereas with a TDi the power is always on tap. They are leagues apart to drive."
And you are most welcomed to try it - when it finished. Up hill I presume?