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Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

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Re: Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

Postby dieselhead123 » Wed Jul 01, 2015 3:20 pm

Altransit wrote:
dieselhead123 wrote:
karl mcghee wrote:what about the bolt fixing behind the inlet pipe

is that a stud fixing


The fixing at the bottom left of the water outlet from the block will be replaced with a stud, the securing nut can be fitted as the elbow plate is installed. The stud and nut will be included in the fitting kit.

TIM

Could that 4th hole under the outlet be 'slotted', in order that a bolt could still be used, but doesn't need to be completely removed to take off the outlet pipe :?:


That's certainly an option Al 8)

The engine has gone off to be fitted in the Mk7 as we needed to progress further with this.
I will be spending a day with the installer, probably next week, 'fine tuning' the installation, so I will get some more pictures up then.

Thanks again for all your help chaps :D

TIM
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Re: Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

Postby karl » Wed Jul 01, 2015 3:43 pm

looking forward to the results of this one :D
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Re: Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

Postby karl » Sat Jul 04, 2015 7:40 pm

should be in now up and running :!:

sorry for the impatience :lol:
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Re: Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

Postby Mr RVM » Sat Jul 04, 2015 8:24 pm

karl mcghee wrote:should be in now up and running :!:

sorry for the impatience :lol:


they've all been getting their own vans ready for tomorrow :wink:
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Re: Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

Postby Altransit » Sat Jul 04, 2015 8:52 pm

Mr RVM wrote: they've all been getting their own vans ready for tomorrow :wink:

Tim has only been getting the barbecue ready :P :lol:
1994 Mk4 SWB 115 Minibus 70ps Di (R.I.P.)
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Re: Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

Postby karl » Sat Jul 04, 2015 8:54 pm

Altransit wrote:
Mr RVM wrote: they've all been getting their own vans ready for tomorrow :wink:

Tim has only been getting the barbecue ready :P :lol:


:shock: only now he is slacking :lol:
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Re: Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

Postby dieselhead123 » Thu Jul 09, 2015 9:33 am

karl mcghee wrote:
Altransit wrote:
Mr RVM wrote: they've all been getting their own vans ready for tomorrow :wink:

Tim has only been getting the barbecue ready :P :lol:


:shock: only now he is slacking :lol:


Don't worry Karl, I am off to the fitter's workshop Friday, we have both been busy with other work.

Not sure if we will get as far as running the engine, although it has been fitted in the van.

I'll get some more pictures and post them up over the weekend.

TIM
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Re: Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

Postby Altransit » Thu Jul 09, 2015 10:00 pm

8) 8) 8)
1994 Mk4 SWB 115 Minibus 70ps Di (R.I.P.)
1997 Mk5 SWB 115 Minibus 70ps Di (Gone, but not forgotten!)
2004 Mk6 SWB T280 Medium Roof 85PS 2.0 TDDi - Vantunered (Also gone)
2008 Mk7 SWB T280 Medium Roof 85PS 2.2 TDCi - Also Vantunered
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Re: Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

Postby dieselhead123 » Sun Jul 12, 2015 11:02 pm

Spent the afternoon with the installer working through a few more bits, should be completed tomorrow.

Just a pic of it 'in the hole';
Image

TIM
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Re: Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

Postby bambi mk 1 » Sun Jul 12, 2015 11:08 pm

What the man said when he cut the monkeys tail Tim .....................Wont be long now :) Wheres the doubters now :?: :lol:
On the sixth day God created a Sprinter on the seventh he gave it away and bought a TRANSIT
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Re: Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

Postby Mr RVM » Sun Jul 12, 2015 11:35 pm

bambi mk 1 wrote:What the man said when he cut the monkeys tail Tim .....................Wont be long now :) Wheres the doubters now :?: :lol:


They're all in the queue at their local "Transit Service" centres waiting to have their fault codes read :lol:
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Re: Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

Postby bambi mk 1 » Sun Jul 12, 2015 11:45 pm

Mr RVM wrote:
bambi mk 1 wrote:What the man said when he cut the monkeys tail Tim .....................Wont be long now :) Wheres the doubters now :?: :lol:


They're all in the queue at their local "Transit Service" centres waiting to have their fault codes read :lol:

:lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol:
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Re: Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

Postby Yaj » Mon Jul 13, 2015 7:07 pm

Dieselhead it sounds great. Mate I got to say I thought the theory was good but in practice even better. People aren't coming in asking for code reading now lol they are all lining up for conversions
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Re: Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

Postby dieselhead123 » Thu Jul 16, 2015 9:36 am

Yaj wrote:Dieselhead it sounds great. Mate I got to say I thought the theory was good but in practice even better. People aren't coming in asking for code reading now lol they are all lining up for conversions


I'm glad that your customer is happy with it, I'm sure you will have many others.

TIM
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Re: Retrofitting a 2.0 Mtdi engine in a 2.2 Mk7 FWD

Postby dieselhead123 » Thu Jul 16, 2015 10:48 am

Now, a bit more on the final install of this.

The intercooler pipework is different to that of the Mk6 so a different fitting for the inlet manifold connection was required;
Image
This bolts to the 2.2 inlet manifold in place of the plastic housing and connects to the intercooler hose using the existing hose clip. Approximately 25mm was cut from the end of the intercooler hose to enable this to be fitted. A hose 'tail' is provided together with the necessary hose to connect to the 'Boost Compensator' on the injection pump.
This adapter housing will be included in the Mk7 kit.

Since we have mounted the Mk7 Alternator at the rear of the engine using the Mk6 mounting points it was necessary to extend the wiring loom to connect the Alternator. Part of the Mk6 loom, (supplied with the engine), was used for this. The Mk7 alternator plug was removed from the vehicle loom and used in conjunction with the Mk6 Alternator loom, this was run up from the rear of the engine as it would be in a Mk6;
Image

We then connected this to the vehicle loom just above the starter;
Image

The Mk7 Alternator has a two wire plug, the Mk6 version has a three wire, so the third wire was left in the loom unconnected at either end.

The Mk7 dip stick tube could not be used in the Mk6 block due to the different diameter of the tube so the Mk6 one was used. The tube was carefully altered so as to clear obstructions and refitted into the block. The mounting bracket was removed from the tube and repositioned so as to support the tube from the injection pump bracket;
Image

In future all pump mounting bracket supplied will be pre-drilled to accept this fitting, a 'P' clip will be supplied to secure the tube with the Mk7 kit.

Next we refitted the vehicle radiator, re-filled the coolant and checked for leaks;
Image

As you can see, access to the injection pump for adjustments is improved when used in a Mk7 compared with a Mk6, the repositioned Airbox is the main reason for this;
Image

Once we had the engine running a while and had carried out a few fueling adjustments to the injection pump we looked at the dash display;
Image

The ABS can be ignored as at this point the engine was running with the gearbox in gear and the front wheels removed. The system 're-set' once the wheels were replaced and the vehicle was driven down the road.

We do however have an Alternator warning lamp displayed but the Alternator is charging :!:
Although at the time of the photo the Crankshaft Position Sensor was not yet plugged in, doing so might even get the rev counter to work :idea:

A number of parts in the Mtdi kit have had to be altered to enable fitting to Mk7, where possible the alterations will be incorporated into the standard parts so as to make them 'universal'. As can be seen from this thread so far, a number of additional parts are also required when retro-fitting into a Mk7, tooling will be produced to enable these to be 'batch assembled' and complete kits will be available soon. Details of these will be posted on the thread as they are produced.

Those of you considering this conversion to their FWD Mk7 should contact us via PM or post on this thread.
We would also like to receive applications from repairers wishing to add their name to our 'global network of approved installers', please use the 'contact us' page on our website for this.

More soon,
TIM
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