AAZ 1.9TD with 1.6TD components

[Joe B]

Guys great forum, keep it up. I have a Polo Classic (marketed in Europe as a Seat Cordoba) gasser which I intend to convert to diesel.  
The IDI motors available locally are all imported ex Europe and Japan, therefore parts are not easy to come by.
Originally looking  for 1.6 TD ( RA or SB but not available ) there were a few JR an MF imported but these seem to have gone scarce, currently can get AAZ 1.9 TD.
Has anyone fitted 1.6TD turbo and injection pump on a AAZ , can this be done and will it work? Anyone done this before? Want to get approx 120 HP out of the motor

[haybayian]

Guys great forum, keep it up. I have a Polo Classic (marketed in Europe as a Seat Cordoba) gasser which I intend to convert to diesel.  
The IDI motors available locally are all imported ex Europe and Japan, therefore parts are not easy to come by.
Originally looking  for 1.6 TD ( RA or SB but not available ) there were a few JR an MF imported but these seem to have gone scarce, currently can get AAZ 1.9 TD.
Has anyone fitted 1.6TD turbo and injection pump on a AAZ , can this be done and will it work? Anyone done this before? Want to get approx 120 HP out of the motor

My  1.9 AAZ is a remanufactured mill. I have followed our local (Toronto) diesel Guru's advice and bolted a Garrett T3 which as I understand equiped the 1.6 L. I have not fired this new engine yet. The pump? I don't know. Others more knowledgeable  here will tell you.

Haybayian

[janb]

I have done this. The 1.6 turbo is larger, thus spools slower, but more boost when it does.  It seems to work well in passenger applications and 1.9 seems to rev high enough to handle it.  For vans and trucks the AAZ turbo is probably best, 'low rpm' power.

[Joe B]

Haybayian, Janb, thanks  mil for your input. I have come across another post of someone who actually used a 1.6 TD pump on the 1.9 and it can be done (from what I have read here I think the 1.6 pump lends itself to more adjustment for power). So I can go ahead and purchase the components to start my first oil burner project. Intend also fitting IC, aux oil cooler and 63mm bore exhaust. Still need to do reasearch on the Rev counter , weather go the electronic internal component conversion route or purchase the Dakota interface box (came accross a post which the person had some trouble getting it to work and support issues), need to find out the make of the board, does not have a manufacturer name such as VDO, Motometer, etc
Once again thanks.

[stewardc]

I have a 1.6 turbo on my 1.9 AAZ. It's a Garrett T-3. I did use the 1.9 pump, though I had Giles work his magic on it.

[bert]

Joe,totally unrelated post but still,had to show you my citi from benoni S.A.





the other one i found in the uk  







Bert

[Torchd]

I wana use AAZ block with MF head, turbo and IP.....  Andrew said compression ratio will be too high?/   does that mean it cant be done??  any way of lowering the CR??


And i wana run a straight exhaust pipe... 3 inches...  is it possible in an mkII...  and where is it suppose to start from???  right from the turbo, from that plate with 4 bolts which mounts on to the turbo..  or does it start after the "C" exhaust clamps...??

[janb]

As far as I Know- I've been running (2) IDI (N/A) AAZ's w/ 1.6 Hyd Heads for 5 yrs.  I ordered them new that way so I didn't have to deal with the changes in the intake ports (1.6 = oval  1.9 = D)  I didn't measure the volume of the pre-chambers, so I can't say for sure.

I also run 1.9 Head Gaskets on my 1.6 TD's to get the 'metal' version, so as you can tell... I don't follow the rules very well  :oops:

[Turbinepowered]

I wana use AAZ block with MF head, turbo and IP.....  Andrew said compression ratio will be too high?/   does that mean it cant be done??  any way of lowering the CR??


And i wana run a straight exhaust pipe... 3 inches...  is it possible in an mkII...  and where is it suppose to start from???  right from the turbo, from that plate with 4 bolts which mounts on to the turbo..  or does it start after the "C" exhaust clamps...??

You can lower compression with a thicker headgasket than you need. It's not ideal, but you can do it. The AAZ heads are going to flow better than the 1.6 heads, why do you want to use the MF head?

If you are doing straight pipe exhaust of that size, you'll want to go from the turbocharger back to get full benefit. I've heard of 3" downpipes, and I believe I've seen one poster here who had a 3" full exhaust.

[Torchd]

Hmm...  cuz i dont have a 1.9 head... thats WHY!!

anyways if i can get the head will i be able to use the 1.6 MF turbo and IP on the 1.9??  will they fit bolt on???

and running the 3'' down pipe and straight through exhaust... will there be any hassle in that??  like not enought space or back pressure???

Cheers!

[Torchd]

And which arp studs fit the 1.9TD??