I have changed my old 1.6 Diesel to a 1.9 from 1999 in my 1983 VW T3 bus. The engine code is AEF and it can be found in VW Polo, Skoda, Seat and Audi. When I started this conversion I was suprised how little information it really was about doing this swap. So I made a video collecting this information and what parts needed and problems that I had to solve. So hopefully this will help others that is thinking about doing this conversion. Good luck!
Yesterday I finished and installed the complete exhaust system. You could use the original 1.6 CS exhaust system if you take the 1.6 header, that’s the easy way. I choose the hard way, using the 1.9 AEF header. Why? Because the exhaustheader ports and outlet are bigger than the 1.6 CS. Which means a little more HP. The problem is that the AEF header have a different angle than the CS one, so need to build a new exhaust system from scratch. The AEF header and enginemount need some grinding to fit/clear.
The original exhaust was 48mm, the new I built is 51mm and the silencer is from a Turbo Diesel, for better flow. Original system was one welded pipe, which I didn’t want to have on a car that should drive on crappy roads and trails. If going offroad and hit a stone not only the pipe would take a pounding but also the head on the engine! I used a flex joint, which now makes the system to flex at least 3-40mm, so hitting a stone or something hard now and the system will just bounce or slide over and the head will be more safe. Also removing some extra vibrations to the car itself.
#vwt3overland #aefconversion
Now with the engine and transmission installed, left to do is connecting electrical wirings and coolant hoses. The AEF engine used a different glow plug relay, but the original VW bus T3 glowplug relay can be used with some modification. I soldered two resistors of total 580ohm to the temp sensor wiring (at the waterflange at top of the engine, black/blue) this will trick the relay and let it glow a little all the time which is needed for the AEF to run clean/nice. The grey/green wire from the pump works like a electric choke at cold starts and can be connected to a timer relay for about 20sec. I bought a cheap timer relay from EBay that would probably work but it was so brittle and crappy. So I didn’t trust it, I just ran a wire to a switch on the dash, will work like a manual choke, almost like original but electrical rather than mechanical, bullet proof too.
Since the old CS intake and air filter box is installed on the little taller new engine, the wires in the engine compartment beside the airfilter needed to be moved upwards (around 60mm) to make space for the filterbox.
I found the diameter on the AEF water pump flange bigger than the old CS which made it impossible to re use the 90degree coolant hose. So I ordered a new 25mm 90degree coolant hose that will be jointed togheter with the old hose.
The crankcase breather need to be cut off in the end, and joined (with metal pipe insert) with the AEF hose. The connection at the cam cover is different on the AEF.
If any one need finished 587ohm resistor for the glowplug relay, let me know and I can ship some out. All you need to do then is cut the wire, crimp on spade connectors on both ends and plug in the resistor. That’s it! info@maindrive.org
Now the engine and transmission is bolted back in the bus, fits perfect! Left to do is all small stuff (But time consuming!) wiring, 587ohm resistor to the glowplug relay wiring, and a timer relay, install all hoses, fill up the coolingsystem with water, gearlinkage, cables, oil and filter, fill up all fuel lines with diesel, prime the pump, build a new exhaust and much more. Here comes some new pics…
