Later Mk5 Di into 1990 Mk3

[ColinJack]

Quick question for the Mk3 aficionados (MinorMatt, AlanN, Dieselhead123, Muttley etc.)

How easy is it to swap my 2.5Di/MT75 lump in my 1990 Mk3 for a later 2.5 Di Turbo and maybe auto box from a Smiley?

1. Would it be straight forward to swap just the engine or better to swap both engine and box?
2. Are the mountings the same or would I need to fashion new ones?

Thanks

Colin

[AlanN]

I know its been done many times in various ways, but Im not up on the engine side of things. From what Ive read on here in the past, you can convert your existing to turbo with a manual pump or fit the loom and TDi from a AndyG super epic

[ColinJack]

I know its been done many times in various ways, but Im not up on the engine side of things. From what Ive read on here in the past, you can convert your existing to turbo with a manual pump or fit the loom and TDi from a AndyG super epic

Thanks. I think Matt has mentioned it is fairly straightforward to convert existing. Not sure on what would be involved with fuelling and compression though. I have only turboed carb petrol engines in the past, so out of my comfort zone on injected diesel!

[dieselhead123]

Unless you definitely want to use the auto box, my advise would be to fit the turbo engine complete, it will fit to the existing Mt75 box you have in the Mk3.
Just use the Mk3 engine mountings and fit a mechanical injection pump, thus avoiding the need to install the Epic management system, something that will be required if you were to use the auto box.
You can transfer the turbo components to your Mk3 engine, you can even keep the CAV pump that is fitted to your Mk3 although most of us do fit the Bosch offering.

TIM

[ColinJack]

Unless you definitely want to use the auto box, my advise would be to fit the turbo engine complete, it will fit to the existing Mt75 box you have in the Mk3.
Just use the Mk3 engine mountings and fit a mechanical injection pump, thus avoiding the need to install the Epic management system, something that will be required if you were to use the auto box.
You can transfer the turbo components to your Mk3 engine, you can even keep the CAV pump that is fitted to your Mk3 although most of us do fit the Bosch offering.

TIM

Thanks Tim,

I like the MT75 box to be honest - and with careful driving I average over 33mpg so not keen to switch to auto.

So the Turbo unit would just drop in (bit of fettling on the exhaust) ... sounds a good option to me!

Appreciate the expert input!

Colin

[captain hook]

If you buy a Turbo engine (Like the one I have for sale )

Make sure you get the exhaust front pipe too

[ColinJack]

If you buy a Turbo engine (Like the one I have for sale )

Make sure you get the exhaust front pipe too

Thought you had sold that one ... will that drop into my Mk3 as Tim suggests?
If so, I may be back.

[transit mark]

If you buy a Turbo engine (Like the one I have for sale )

Make sure you get the exhaust front pipe too

Thought you had sold that one ... will that drop into my Mk3 as Tim suggests?
If so, I may be back.

Barry proberly has a couple lol

[captain hook]

Just a couple

[ColinJack]

Right - have just returned with my new donor vehicle. Exciting stuff!



Bought 2000 Torneo van remains from stevescaravans - top bloke, well pleased. I have the complete engine bay, so making it all fit should be relatively straight forward according to Tim (diesel123) who will supply me the necessary bits to convert to Bosch etc.

I intend to keep the MT75 box. The current engine has a bosch pump fitted, but I want to lift that engine out complete and stick it on a palette as a drop-in spare (just in case). It has only done about 100k. The new one has done 166k but looks fine.

New engine will have EPIC removed and new Bosch fitted. Remove EGR and clean out inlet manifold. Replace cam belt, water pump and all other belts. Currently has brown spot injectors. Hopefully can get advice (from Matt or Tim or Andy etc.) re getting the fuelling right. I have a friend & neighbour helping who buys and sells plant, so knows a bit about swapping engines and has a fully kitted out workshop

This is a camper so fuel economy and reliabilty are paramount - we do a lot of driving around Europe. I do want it to whizz up hills though! Gets embarrassing chugging up gentle hills at 25 mph!

I hoping this will be the answer to our prayers.

[ColinJack]

Job done!

Donor turbo engine in and just been for first run. Sounds really good!

So far:

2000 TDi engine from donor vehicle
New cam belt, water pump, filters, engine mounts etc.
Removed EGR totally, cleaned out inlet manifold
Removed EPIC and fitted Bosch 108
Removed ALL extraneous crap - oil cooler, sound proof cowlings etc.
Fitted cold start advance unit from original engine
Bosch pump timing set as per dieselhead123 instructions (0.68mm advance)
Large SVO clutch fitted

To do:

Make smoke (play with fuelling)
Fit intercooler (just got to rig some fittings)
Invent & fit air filter - LHD so standard TDi one won't fit.

Appreciate all the help from everyone so far (Tim, Matt, Andy etc.) - running sweet as a nut!
Just need to get the power up a bit now ...

[dieselhead123]

Glad you got it going mate, well done

I hope you are going to leave a 'gap' in your European tour ti visit Transitmania, I am sure we would all love to see the van.

Stay safe,

TIM

[ColinJack]

Glad you got it going mate, well done

I hope you are going to leave a 'gap' in your European tour ti visit Transitmania, I am sure we would all love to see the van.

Stay safe,

TIM

It is already in the diary but will depend on 'her who must be obeyed'

Enjoying the Chucklebus developments ... when are you fitting the blower?

[dieselhead123]

Hope you get to Mania mate.

The intention is to have the larger turbo and chargecooler on the 'Chicklebus' in time for North Weald but i keep 're-designing' the set-up , then I wait for parts to arrive, then 're-design' again etc!
It will be off road next month for some more panels, near side front this year, so the flywheel and clutch will get fitted before the new MOT.

If I am not too busy in the workshop then one month will be all I need!

TIM

[camper-man]

If this engine is from the van I think its from(my old auto- tourneo)Its a fantastic engine I sold the tourneo to stevescaravans.