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Mk1 SWB flat front pop top camper to VW 1.9 tdi PD engine

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Mk1 SWB flat front pop top camper to VW 1.9 tdi PD engine

Postby RP123 » Mon Feb 22, 2021 11:12 pm

I’ve made a start on my VW 1.9 TDI conversion into my MK1 swb and thought I’d start a thread for the conversion, however I maybe a bit slow to update as time on here is precious time in the workshop building :lol:

I got myself a 2004/2005 VW Passat 1.9 TDI AWX engine code so 130 bhp for the engine and any other bits I might need for the conversion, I’ve got the engine out complete and ECU and engine loom and stripped back the dash loom of the Passat for the plugs that plug to the engine loom, I had planned to use a MT75 gearbox and adapter plate to mount the two but decided against it recently as I don’t want to cut the Mk1 about for the MT75 to fit and faff around with a prop shaft so after much deliberation I’ve decided to use a type 9 with the transit bits fitted so stick is in right place, two reasons for using type 9 are, 1; a bellhousing is available off the shelf from RWD Motorsport to mate the type 9 to VAG 4 cylinder engines (they list it for fitting the petrol 1.8 turbo VW and Audi engine but also say it fits the 1.9 tdi’s) and 2; I won’t have to cut the van about for the type 9 or muck around sorting a prop shaft like I would for the MT75. I know the type 9 is not overly favoured for the Transit but my theory is, it’s a swb van not being used to carry heavy goods, I’m going to uprate with better bearings etc and providing I don’t give it lots of abuse and drive it accordingly I think it will be ok, if not I’ll reconsider my gearbox options for it, I’ve got a few transit type 9’s spare now plus a car V6 type 9 which I may even use for the conversion.

So I’ve got my bellhousing got my tdi engine out and got the V4 and gearbox out of the van in preparation, over this weekend I set about mating type 9 to tdi engine with the RWD motorsport bellhousing and this is when I realised that they drill the bellhousing to gearbox holes so that the engine and gearbox are level mounted as apposed to the engine being ‘leant over’ in its VW installation, there was a solution to this as the rear face of the bellhousing is concentric to the centre bore so I was able to redrill the holes so now the gearbox is level while the engine is canted/leant over as per original VW installation, bonus. I need to muck around with the clutch still and clutch operation is by means of a mondeo hydraulic release bearing assembly (bell housing is already designed/machined for this)

Ive temporarily got the engine and gearbox in the van ready to fabricate engine mounts and get everything else fitting up before pulling it all back out again to paint engine bay, it needs to go slightly higher in the bay and back a little more to get gearstick to line up with original hole in the floor and to give a little more space at the front for radiator but it’s tight to say the least!

Some pics of where I’m up to before updating again.
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1999 Tourneo GLX85PS
1973 Mk1 Transit Canterbury savannah
1963 Mk3 Zodiac
1964 Anglia 105e
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Re: Mk1 SWB flat front pop top camper to VW 1.9 tdi PD engin

Postby Luke » Tue Feb 23, 2021 12:20 am

nice to see pics 8)

what flywheel are you using?
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Re: Mk1 SWB flat front pop top camper to VW 1.9 tdi PD engin

Postby RP123 » Tue Feb 23, 2021 12:24 am

Cheers Luke, I’m probably going to stick with the standard dual mass flywheel
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1999 Tourneo GLX85PS
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1963 Mk3 Zodiac
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Re: Mk1 SWB flat front pop top camper to VW 1.9 tdi PD engin

Postby waerhy » Sun Feb 28, 2021 7:58 pm

What is the type 9 gearbox from?
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Re: Mk1 SWB flat front pop top camper to VW 1.9 tdi PD engin

Postby RP123 » Tue Mar 02, 2021 2:36 pm

waerhy wrote:What is the type 9 gearbox from?


Some Mk3 transits were fitted with type 9 5 speed gearboxes, they differ slightly to the ‘car’ version of the type 9 in respect to the gear lever position.
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1999 Tourneo GLX85PS
1973 Mk1 Transit Canterbury savannah
1963 Mk3 Zodiac
1964 Anglia 105e
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Re: Mk1 SWB flat front pop top camper to VW 1.9 tdi PD engin

Postby Luke » Tue Mar 02, 2021 6:14 pm

RP123 wrote:
waerhy wrote:What is the type 9 gearbox from?


Some Mk3 transits were fitted with type 9 5 speed gearboxes, they differ slightly to the ‘car’ version of the type 9 in respect to the gear lever position.
and i think the output shaft is longer ? like the v6 and diesel sierra ones :?:
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Re: Mk1 SWB flat front pop top camper to VW 1.9 tdi PD engin

Postby RP123 » Tue Mar 02, 2021 8:38 pm

Luke wrote:
RP123 wrote:
waerhy wrote:What is the type 9 gearbox from?


Some Mk3 transits were fitted with type 9 5 speed gearboxes, they differ slightly to the ‘car’ version of the type 9 in respect to the gear lever position.
and i think the output shaft is longer ? like the v6 and diesel sierra ones :?:



Your probably right Luke but the 4 Transit type 9 gearboxes I have the input shafts are all shorter than the v6 type 9 gearbox I have :?:
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1999 Tourneo GLX85PS
1973 Mk1 Transit Canterbury savannah
1963 Mk3 Zodiac
1964 Anglia 105e
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Re: Mk1 SWB flat front pop top camper to VW 1.9 tdi PD engin

Postby RP123 » Sun Mar 14, 2021 9:47 pm

Progress a little slow but eventually got the engine further back in the engine bay so that the type 9 gearstick lines up with the original hole in the floor, had to ‘pocket’ the bulkhead slightly to enable this. The plus side moving it back slightly more has given more room up front for the radiator. Engine mounts all fabricated I’ve been able to retain the Passat mounts and rubbers and made brackets on the van for the mounts to fit to. Just need to mount the transit type 9 gearbox crossmember now.

A couple of pictures
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1999 Tourneo GLX85PS
1973 Mk1 Transit Canterbury savannah
1963 Mk3 Zodiac
1964 Anglia 105e
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Re: Mk1 SWB flat front pop top camper to VW 1.9 tdi PD engin

Postby RP123 » Mon Mar 29, 2021 9:01 pm

A little bit of slow progress, made the gearbox crossmember. Originally I was going to adapt the Mk3 Transit type 9 gearbox crossmember to fit my van but made one from scratch instead. Next job is to work out cooling radiator and pipe work along with where to fit an inter cooler and all the pipe work for that.
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1999 Tourneo GLX85PS
1973 Mk1 Transit Canterbury savannah
1963 Mk3 Zodiac
1964 Anglia 105e
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RP123
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Joined: Tue Dec 06, 2011 10:09 pm
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