Mk2 Engine Change to a 2.5 diesel. No Idea what I'm doing

[FredTransit]

that's a bit extreme mate!! The front crossmember is very structural, which is why it's a test failure if you have rust on it. Still it's your van and if you are happy doing that.....

[madmark]

well i found the york engine was very good i had one fitted in a mby and it pulled like a train !

[Retrohowla]

Yep like i said it would raise a few eyebrows but was patched badly when i bought it so now it is brand new metal throughout
Like i say if you can weld properly is not a problem, well shes passed an MOT since and the tester asked where i got the welding done as he was impressed it had been done properly

[Luke]

ive never removed the crossmember - even on a van im scrapping but i suppose it would make it easier

drop the gearbox crossmember off and let the box hang down sling it on the engine and with a chain block or engine hoist the lot comes out the front easly

[Retrohowla]

I dont know why but when i tried to offer the DI into the mk2 it just didnt want to go, so knowing i was looking at a new X-member anyways i removed it and in she slid
I did also have to make the new X-member with a cut out for clearance for the fan im not sure why but my conversion seemed very tight (airbox hitting bulkhead and fan only just clearing X-member)
Maybe i missed a trick somewhere?

[FredTransit]

You can put the banana air box to the right of the engine under the battery, we did that when we fitted the engine, keeping the original manifold.

[Retrohowla]

Yes i remember you saying when i was doing the conversion but the plan is to mount an aux alternator for charging my bank of batteries the inverter runs off as most places i stay have no power points.
The only place i can see the second alternator will fit might foul the banana type airbox
As it stands though the Di is in and running with the airbox just touching the bulkhead, not ideal i know but its never gonna be perfect.
I was however thinking if i could get some slightly thinner engine mounts it would drop it just enough for the airbox to clear?

[FredTransit]

Now you mention it, putting the air filter housing on top of the engine should be OK, that's where they were originally when the DI was an option on the Mk2. I would not recommend thinner anything when mounting a heavy engine like a DI!

[Retrohowla]

Yeah i think the air filter box used with the di in a mk2 is slightly different to the one used in the mk3/4 pre banana hence my struggle. (was the mk2 filter box metal? mine is plastic)
The reason i say thinner mounts (im referring to rubber mounts not steel parts) is because i spotted some on a boat i was working on and looked like they would of done what i wanted and are rated for much bigger engines than the di the only trouble is because rubber mountings are not used allot in the marine industry im finding it hard to track down the supplier
I take on board what your saying about the weight etc but like i say i have looked into ratings to be sure i wont end up with a motor dragging down the road
Again though im just putting my ideas out there really as my brain works overtime sometimes and i miss the simplest solution....................hang on! why dont i fit a mk2 filter box!!!???????

[FredTransit]

I will get you a pic of the Mk2 factory diesel when Gary gets back from work. The Mk2 filter box is plastic.

[Retrohowla]

Is it right? thankyou very much that would be great! I am going to a mk1/2 brakers this weekend so will have a look and see if i can find something the same as yours (if it differs from mine) then i might be able to get some soundproofing on the bulkhead at long last

[Luke]

I will get you a pic of the Mk2 factory diesel when Gary gets back from work. The Mk2 filter box is plastic.

so what are the metal air filters off - i always thought they are mk2

[FredTransit]

I will get you a pic of the Mk2 factory diesel when Gary gets back from work. The Mk2 filter box is plastic.

so what are the metal air filters off - i always thought they are mk2

Not seen a metal one fitted as original, at least not to the ones I know haven't been messed with (86 on) the earlies could have been metal I suppose. Mk1 filter housings were metal.

Do me a favour Retro, whilst you are at that scrappy see if you can find me an early Mk2 wheel, the flat plastic one with 3 spokes and the small round centre cap please. They were also fitted on all of the Mk2 ambies.

[Retrohowla]

Do you have a piccy? This is whats fitted to mine, is this the type you mean?
Sorry but as this is my first mk2 ive not seen any others

[FredTransit]

That's the one I want, it's the early Mk2 type.