1.9TD to 1.6TD swap ??? - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• 1.9TD to 1.6TD swap ??? by WreckerMagoo on 03 May, 2008 20:49
• I have a "94 golf with a 1.9Td that just bit the dust on me. I had it towed to the mechanic, he looked at it for about 30 seconds while I tried to turn it over and said "metal is hitting metal, that's not worth fixin"
  obviously that's not what i wanted to hear, 'cause I just bought it about 6 months ago.
  Well it just so happens that my neighbor had a 1.6TD in his garage that he bought years ago with an older jetta as a spare motor, supposedly running fine when pulled. So he traded it to me for a bunch of scrap metal  :D
  now to the question(s)
  basically I guess I'm lost as to what to do, what parts will swap over, will the engine slide right in?
  the 1.9 was in great looking shape with a rebuilt fuel pump and just about everything else while the 1.6 looks like a rusty hunk of scrap metal :x  but it does have the turbo and fuel pump intact.
  Suggestions?
  Advice?
  Questions?
  Anything :?
  
  TIA
  Wrecker
• #1 by Vincent Waldon on 03 May, 2008 20:55
• Pretty much slide right in, except for the electrical.
  
  If you can look at them both side-by-side you'll notice that the 1.6 doesn't have the big black electrical connector by the head that all the engine wires run thru (glow plugs, IP, oil pressure senders, etc etc).  The alternator is different and so has a different harness as well.
  
  With a little tracing it will all line up with butt splices, but it will take a bit of detective work. NP if you don't mind schematics.
  
  Oh, and I'm not completely sure about the downpipe to exhaust connection.. the 1.9 downpipe connects to a catalytic converter that's not present on the 1.6.
• #2 by WreckerMagoo on 03 May, 2008 21:04
• electronics/wiring/schematics are my thing. it's mechanical fuel pumps ,turbos etc that I don't have much knowledge of. thanks for the reply vince.
  should i keep the 1.6 with it's old fuel pump or try and swap the rebuilt one from the 1.9 over? I don't even know if it's the same or interchangeable.
• #3 by Vincent Waldon on 03 May, 2008 21:15
• Then you're in great shape... the mechanics are 1:1 (with the possible exception of the exhaust connection at the bottom of the downpipe).
  
  The injection pumps are different, as are the injectors and injector lines.  So your best bet is to just swap engines complete.
  
  If you want to make some extra coin you can part out your old 1.9 engine... the injector pump and injectors are always in demand as is the K-14 turbo you probably have.  Also the alternator, starter, crank,even the  head and/or pistons depending on the damage.... ;-)
  
  Somewhere on this site I believe theres a list of people chomping at the bit to get ahold of some 1.9 injectors....
• #4 by vdubin_g60 on 03 May, 2008 21:23
• If you do end up parting the 1,9  i need a k14 turbo.  let me know thanks
• #5 by Patrick on 04 May, 2008 03:54
• The easy way out on the exhaust is to use the 1.9 exhaust, it will hook to the turbo in the 1.6 if you can get the bolts out and remove the cast toilet bowl setup. You might want to use turbo and all from the 1.9, it will spool up a lot quicker than the turbo that's on the 1.6. Just a little plumbing involved for the oil return.
• #6 by WreckerMagoo on 04 May, 2008 10:57
• "The easy way out on the exhaust is to use the 1.9 exhaust, it will hook to the turbo in the 1.6"
  
  Thats good to know because the downpipe on the 1.6 has been cut off with a  grinder, so it looks like that is my only option.
  I was just out looking at the 1.6 and noticed that the injector lines are MIA, although the injectors are still there. Are they expensive? or hard to get?
• #7 by WreckerMagoo on 04 May, 2008 11:16
• On another note, I'm still contemplating whether I should really do the swap or just get my 1.9 rebuilt. I would like to get a second opinion on the damage and $$ to get it fixed. The mechanic I took it to was the only non-dealership VW mechanic in Kingston and i found out after I had it towed there that he mostly only works on gas cars. I don't think he even wants to take a good look at it. I might have it towed to someone else (between Montreal and Toronto) and get a second opinion because I'm not sure of the condition of the 1.6 and neither is the guy I got it off. I would hate to do all that work and bastardize my nice little car to find out it doesn't run well, or dies soon after. All I have is the word of my neighbor who was told by the guy he bought it from that it ran, and it's probably been sitting in his garage for years now. I trust my neighbor but I don't physically know anyone who has actually seen it running.  :?
  
  if I do part out the 1.9 I will be sure to come here first and offer up the parts, you guys have been really helpful.
• #8 by jtanguay on 04 May, 2008 11:45
• well if he's saying metal is hitting metal, maybe the timing belt slipped due to the crank nose issue?  some places charge about $600 for the crank nose fix.  if you were rebuilding the motor yourself and took the crank to a machinist, they could probably have it done cheaply, maybe $50 bucks or so? (to accept the TDI crank sprocket)
  
  and then you need to buy some new valves...  and you might as well buy some new bearings (bottom end bearings, intermediate shaft bearings too) and new rings at this point may be a good idea.
  
  it is quite a bit of work, but the 1.6 you have might be on its last legs, and only go so far, and is less powerful. however the 1.6 is the cheapest option.
• #9 by lavabo on 05 May, 2008 11:31
• put the 1.6td in for now,
  
  then take your time rebuilding the 1.9td
  
  when its done, swap back the 1.9td in!
• #10 by WreckerMagoo on 05 May, 2008 12:56
• I think that is what I'll do.
  swap in the 1.6 then take my time on the 1.9 or look for a rebuilt block in the mean time.