Will a 1.6 TD fit where a 1.9 idi was?

[homerj1]

Sorry about the confusing subject line - but here goes.

I have a 1.6 td engine that is in ok shape. Am looking at a 1995 Jetta that has a blown 1.9 idi engine.

Could I put my 1.6 td into this car? Would the engine bolt right in?

Would I need to alter/modify anything major or minor?

Any pros or cons of this swap?

Thanks

hj1

[burnt_servo]

the belts and pully's between the engines will be different ,v belts vs flat ribbed belts on the 1.9 .

 and the 1.9 block is a bit taller , so your exhaust might have to be trimmed down a bit .

can't see it being that difficult ... anyone else ?

[burn_your_money]

It's a pain in the ass IMO. I've done it with that exact same car

You'll need a custom downpipe or exhaust since the AAZ most likely has a K03 on it.
You'll need to swap the flywheel/clutch over to use it with the AAZ tranny. The AAZ tranny will be pretty tall for the 1.6 (certainly not unbearable though) and swapping in a mk2 tranny will involve swapping axle flanges as well as getting the electric speedo to work
You also need to swap over all the coolant sensors/flanges
Rear motor mount needs to be swapped
Air box will not line up properly but a mk2 one can be used
Alternator has different connections on it so you'll need to do some splicing

That's all I can remember off the top of my head

[homerj1]

It's a pain in the ass IMO. I've done it with that exact same car

You'll need a custom downpipe or exhaust since the AAZ most likely has a K03 on it.
You'll need to swap the flywheel/clutch over to use it with the AAZ tranny. The AAZ tranny will be pretty tall for the 1.6 (certainly not unbearable though) and swapping in a mk2 tranny will involve swapping axle flanges as well as getting the electric speedo to work
You also need to swap over all the coolant sensors/flanges
Rear motor mount needs to be swapped
Air box will not line up properly but a mk2 one can be used
Alternator has different connections on it so you'll need to do some splicing

That's all I can remember off the top of my head

Thanks for the informative reply. A few clarifications.

1. The 1.6 will bolt up to the AAZ trans. if I use the 1.6 clutch & flywheel ? Although tall gear ratio of AZZ trans is a bit of a bugger?

2. Coolant sensors from AZZ need to be used in 1.6. Unsure what flanges are? (for sensors?- stat housing?)

3. Air box, motor mount and alternator seem to be easy DIY?

Thanks again for your help!

Homer J1

[Patrick]

Make the 1.6 look like the 1.9 and put it in (including clutch and flywheel). Not sure about the trans gearing, lots of 1.6 engines were hooked to 3.94 diffs and .75 final drives. You should be able to look up the gearing if you can read the code on the bellhousing.
If you've got a k14 on the AAZ, the exhaust will bolt right up. If it's teh K03, you might want to put it (or the k14 for that matter!) on the 1.6, it will spool a LOT faster. Only problem there will be the return line for the turbo, you'll need a custom one or have to fabricate to make the two lines you have into one (oil return is in a different place).

I'm driving an AAZ in a mk 2 jetta, doesn't look a lot different under the hood. If it works that way (mk3 engine in a mk2) it will work your way(mk2 engine in a mk3 car).

[burn_your_money]

1. The 1.6 will bolt up to the AAZ trans. if I use the 1.6 clutch & flywheel ? Although tall gear ratio of AZZ trans is a bit of a bugger?

2. Coolant sensors from AZZ need to be used in 1.6. Unsure what flanges are? (for sensors?- stat housing?)

3. Air box, motor mount and alternator seem to be easy DIY?

1. Yes it does bolt up. You'll need to check to see if the 1.9 tranny has different splines then the 1.6. I used the 1.9 tranny with the 1.9 flywheel.

2. Yes you need to use the AAZ coolant sensors on the 1.6 because they have a different connection on them. This means you also need to swap the coolant flanges over. I think I had to change the oil pressure switches too because the low oil pressure light came on even though I knew the engine had good oil pressure.

3) yes they are simple. Just something else to consider.

AAZ trannys typically have a 3.67 final drive which is what makes them seem tall and sluggish, but as I said, not unbearable. With the one I was using (CHD I think) driving at 90 kph was hellish because it was too short for fourth but too high for fifth. The solution is to drive 105

[homerj1]

Thanks Guys for all for the great responses!!

[GTD.]

and swapping in a mk2 tranny will involve swapping axle flanges as well as getting the electric speedo to work/quote]

Speedo sender fits in a mk2 gear box, I'm using a mk3 sender for my mk3 clocks, going to use it for when I fit my VDO's instead