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!
Just some random pics from last month on the T3 Highroof or as my son calls it “The Monster bus” 🙂
The old 1,6 CS diesel was a bit to slow in hills/highways (to the point it get dangerous in traffic). So it needed to go. I don’t going to race Lemans with the bus, I just want a more modern, stronger, cheap to drive (diesel) and most important RELIABLE engine that always work. First I was looking at a AAZ 1,6/9 Turbo engine but with a turbo it’s just another thing that can brake and these engines always runs much hotter. So I decided to go with a VAG 1,9 AEF engine, found in VW Polo, Golf, Audi and Skoda Felicia.
THE NEW ENGINE
I managed to find a really lowmilage 1,9 AEF diesel engine from a Skoda Felicia, year 2000. But it is not just to bolt this engine in the bus and drive, a lot of stuff need to be changed and parts from the 1,6 CS need to be re-used and modified. But its probably the easiest conversion you can choose, if your thinking of using a non standard engine in your VW T3 diesel bus.
TRANSMISSION
While the engine is out I will also take out the transmission. And make a check up, change shifter couplings, linkage bushings and gaskets. Upgrade driveshafts to stronger, Porsche. Upgrade the differential with a difflock from Weddle Ind. In a standard “open” differential, torque is divided equally between the wheels. If one wheel slips and spins, only a fraction of the torque is utilized. The difflock eliminates this problem. Power will always be delivered to the wheel with the most traction to keep you moving instead of getting stuck, up to 100%. Then it we can do some serious off-roading 🙂
More to come soon! #vwt3overland
If anyone need new wheels, tires, installed and balanced to a good price. Send me a message on: info@maindrive.org
The interior is almost finished now, just some small details left to do. Here is how it looks so far… it so nice with heater on the winter, it was -9 celsius and inside was set to 26+celsius 🙂
#vwt3overland
The wiring was a mess (for all equipment) so a new control panel with automatic fuses was installed togheter with new wiring. The 230v wiring (camping power) was also updated with automatic ground fuse and two new sockets with combined USB outlets.
The old interior lightbar was only 230v, but it was a great design so you can flip/turn the light angle. So I took it apart and converted it to 12v with LEDs. An extra LED light with two touch dim/settings was mounted up in the front of the sealing/roof also.
Under the rock n roll sofa I made space for 200amp of batteries (dual 100amp). These I connected to the car/start battery thru a relay, so the car alternator will charge all battery’s. These batteries are connected thru Bluetooth to my cellphone so I can see how much power is left and how much is charging. The solar panel (portable 120w) have a quick connection to these battery’s. Also the 5kw diesel heater is installed under the sofa. It takes air from outside and diesel from the main tank, and the exhaust is routed thru a silencer and out. It runs on diesel and 12v so it can be used anywhere for a very longtime, no need for 230v power. It has a digital display, and a thermostat so it will keep the inside toasty warm on winter. It can be started thru GSM net with my phone. I routed the heater outlets to the main floor and one to the back/bed. It works great and produce a lot of warm dry heat!
The walls, doors and roof was already insulated with 50mm cellplastic, thats very good! But I had some extra aluminium/bubblefoile rolls that I put inside some of the doors and walls for some extra insulation and vapor barier.
#vwt3overland
Have been working on the camping interior lately. The old interior was crappy and looked like shit, it had some structure wall weave/papper that hade been rolled with paint 10 times, the touch and feel was like a 40 grit sandpaper so it needed to go. But it was a good design/plan layout on the cabinets and storage. So I decided to keep the base of it and make a new outside finish on it in light grey oak vinyl.
All cabinet doors was made new in 12mm Medium Density Fibreboard and painted in medium gloss grey with paintgun. Countertop was made new in black colored MDF with semi-gloss clear coat, now with space for a portable kitchen / stove. Above the stove space I made a 12v kitchenfan with outlet, the fan is moving 3,8 squaremeters of air per minute so now you can make bacon with closed doors without smoke/smelling anything 😉
All the old gas equipment was removed, and the old fridge was replaced with a modern 12v Waeco 48L fridge with freezer. A new black sink and a new Reimo water tap was mounted. And all new waterlines, pump and 20L freshwatertank. Before the water ran straight out on the ground, now it goes into a 10L tank first, with a valve so the water can be emptyed. This is good of you are using water when you are on a parkinglot, ferry or on a big camping with neighbors.
Part 2 is coming on Tuesday…
#vwt3overland
Another generation to the collection, at the moment I now have T1, T2 and T3 buses. This one is going to be the offroad bus and for autumn/winter camping/expeditions 🙂
It’s a 1983 Transporter with 1,6 Diesel and 4-speed transmission. It has a ugly camping interior already fitted that will get a refresh/restoration. A Webasto/Planar diesel heater with thermostat will be installed to the interior in future, so you can stay warm on the winter. New 12v fridge will be installed and the gas stove will be replaced with a new small portable gas bottle one.
The goal is to have it pass the MoT / Safety Inspection before the winter comes. The engine starts but is not running very well. It has a new cam, timingbelt, waterpump at the moment. Going to align the timing belt better because it squeaks at lower RPM right now. Also the diesel pump is needing adjustment with special VW TOOL 2066.
Some meaty offroad tires (Malatesta Kobra) have been fitted on stock VW 14″ steel wheels, that was sandblasted and painted. Looks badass now! The diesel tank have been drained on old diesel and a new fuel filter fitted. Also added some anti-bacteria and injectioncleaner to new diesel. New oil (15w-40 mineral) and filter in the engine too. New air cleaner filter added. Injection pump adjusted with micrometer (vw2066) up to 00,95, before was only 00,81. Engine now runs much smoother but need to align the timingbelt before any real test drive can be done. More too come soon… 
Some pics from this summer.
Bennys VW T3 bus finally finished. Here is some BEFORE and AFTER pics. 🙂
Today the bus was dropped of at the glasshop for new front windscreen and installing all windows with new rubber seals. The last final parts (bumpers) are getting painted tomorow or on Thursday. They were handpainted with brush, twisted, rusty and lots of small dents. After sandblasting they got welded, straightned and all dents hammered out. Then a light coat of bodyfiller to make them straight again, then Zinc rustprimer and after this surfacer/ground primer to get them smooth again after the sandblasted surface. Next up is some more sanding and then Deepblack paint. New covers and bolts are waiting from Just Kampers! The bus should be ready for the road in the end of the week! More pics to come…
Trying the fitment on the new wheels on Bennys T3 bus. Its going to be a badass car! 
After alot of bodywork and sanding it was time for topcoat paint in VW Marsala Red H3D. Looks nice in red! Also got new Deepblack paint on the sun grey faded trim and parts like the front grills, handles, air intakes, wipers etc. I think all the black parts will match the black wheels perfect when its all together. The wheels from Germany will arrive this week and the other new VW parts from Just Kampers will be here tomorrow!
Time to sand the primer and fix small dents and scratches, and its alot of them both. When this is done a new coat of grey primer/filler is needed to get a good even base that needs a light sanding with 800 grit by hand before paint! Alot of work for sure!
All the places that have been sanded and sandblasted down to the bare metal have been painted with yellow 2k epoxy rust primer for protection. After this, all the small dents, scratches and imperfections in surface/metal after sandblasting etc have been filled up and sanded smooth and all the seams have been sealed up with new seamsealer. Then it was covered in yellow epoxyprimer again. When it was all dryed it just needed a light sanding before 3 coats of grey surfaceprimer was added. Now it has to dry a couple of days before it can be sanded down again, but this time more carefully and must be perfect! When this is done its ready for topcoat paint in VW Marsala Red H3H3.
Bumpers and some smaller parts is at the sandblasters at this moment and more new parts from Just Kampers in UK is on its way right now. Time to choose some cool wheels also, stay tuned for more pics and updates!
Maybe these 17″ wheels? 🙂
Some updates! All windows are out, all rust is repaired and the body have been sanded. Now the body work can start and I hope to have it in primer next week. Then its ready for more sanding and smaller bodywork before topcoat goes on. Maybe VW Marsala red paint?
Yeah the winter season is definitely here. It’s -10 celsius (14 Farenheit) outside here in Sweden. But days like that are perfect for ordering new VW parts with a cup of coffee in the other hand. Im making a loong list of new parts for the Baywindow Highroof project and also new window rubbers etc for the VW T3 transporter. After 10 years of building VW’s I finally found a serviceminded VW part store that have great quality on their stuff too!
Im now buying all my new parts from JUSTKAMPERS instead. They are based in the UK but ships worldwide, cheap shipping prices and have the best service you will ever find from a VW shop. I can really recommend these guys, take a look at their website here!
I also got some stuff done on the Highroof, removed all brakes, masterbrakecylinder, booster, steeringrods etc front beam soon ready to get dropped down and put on the table for some restoration (new needle bearings, balljoints, bumpstops, kingpin bushings etc). Hope to get started on the metalwork on Benny’s T3 soon also…
