200 TDi Conversion problem

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docrobby

New Member
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18
Hi:
I have a problem attempting to convert my ex-MOD series 3 109 to a 200 TDI.
before installing the new engine I could easily turn the engine with a wrench.
The installation was fairly difficult. It took my son and I two days to put the engine in.
We just couldn't get it to mate up. We jockeyed it around and tilted it this way and that and spun the driveshaft to attempt to line up the splines and finally it just went in but still was stuck about 3/4" to 1" away.
After getting it installed we had to pull it the last 3/4" or so with the studs and nuts.
Here's the problem. Now we can't turn the engine. The transmission is in neutral and there are no drive shafts installed so- what could be causing this?
Is there anyway it could have mated up with the clutch wrong? I don't see how. The only place for the transmission shaft to go is in the clutch.
Any ideas out there?
Nobody here in New Mexico has done this conversion so I am looking to the source.
Thanks:confused:
 
Last edited:
If the clutch pressure plate is slightly off it will be a tiny bit off centre,

have you got the clutch pedal connected up to it yet? try pushing the clutch down, maybe it'll align itself and free up.

We had this problem quite recently, fitting a V8 into my sisters 90.. it was a real nightmare to fully mate up - in the end I took the HT lead off the distributor and turned the key for a second - and it plonked straight in.

did you check the gearbox before fitting it? maybe it's stuck in gear
 
pulling it up the last 19mm with nuts ,series box is a tight fit on studs it needs to be exactly inline with gear box held securely so it cant move up/down ,try that when you put engine back in ,if you need to fit longer studs one either side and use springs and tighten nut to apply pressure till it goes home completely,check spigot bush
 
Sorry for the delayed response. I have been in Philadelphia for the last week and had no computer access.
The transmission is good and with no drive shafts installed I am hoping that the comment about the sightly off-center clutch is correct.
I need to install the clutch fork and bleed the clutch (I just installed a new clutch master cylinder and master cylinder to flex pipe).Then I will give it a try.
Thanks for your replies.
 
I had lots of trouble getting my 200tdi into the series, pratted about for ages, in the end took it out and re-aligned the clutch and it slid straight on :) I did have to pull the last 10mm or so with the studs as said but its still there and working now :)
 
Sure enough! Disengaged the clutch a couple of times and the engine turns no problem.
Now it's on to the next perceived problem.
Thanks, all, for the help!
docrobby
 
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