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Author Topic: Converting a 1.9 head to instal on a 1.6 mech. block  (Read 48101 times)

Reply #30October 10, 2008, 09:55:11 am

saurkraut

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Converting a 1.9 head to instal on a 1.6 mech. block
« Reply #30 on: October 10, 2008, 09:55:11 am »
There is no question that virtually any combustion process is more efficient the higher you go in compression.

The mechanical conversion of that combustion process starts to go to crap somewhere around 17:1 due to cranking loss.

Look at the TDi motors.  They're 19.5:1.  Why didn't they opt for the 'much more efficient' 23:1?  I suspect mechanical losses.

There is a VW white paper for the 1.5 that goes into detail on this.  I'll try to find it and post it.

Mean while, back at the project; I ordered a set of the Crespo mechanical cam followers.  So I should have them next week.

I'll be pushing out the 8mm guides, and my super-wiz-bang shims.  Then its new guides, and the hydro valves, springs, seats, keepers and colletts.  Next weekend is shot, So hopefully the weekend after that I can have fire in the hole, and we'll see what this head will do.
'79 1.6TD RABBIT
'84 1.5TD RABBIT
'83 Diesel Westy
'86 Audi 5000 Turbo Quatro Wagon
92 Audi 100
'93 Eurovan
'82 Porsche 930

Reply #31October 13, 2008, 03:34:42 pm

Turbinepowered

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Converting a 1.9 head to instal on a 1.6 mech. block
« Reply #31 on: October 13, 2008, 03:34:42 pm »
If you take the shims out, won't that let the valve guide once again protrude into the port area?

Reply #32October 13, 2008, 03:52:35 pm

saurkraut

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Converting a 1.9 head to instal on a 1.6 mech. block
« Reply #32 on: October 13, 2008, 03:52:35 pm »
Quote from: "Turbinepowered"
If you take the shims out, won't that let the valve guide once again protrude into the port area?


Yup, Pushed them out and put in new guides this week end.   And they REALLY stick out now.

I glanced at the Vizard article, and I couldn't tell if the had removed any of the valve stem in the port.  I'll have to look closer at it.

Here's the receipiant.  Patently waiting for the new head:



The solid lifters are in transit.  I got the new valves already.  Pritty soon.

I hope winter holds off for a few more weeks....
'79 1.6TD RABBIT
'84 1.5TD RABBIT
'83 Diesel Westy
'86 Audi 5000 Turbo Quatro Wagon
92 Audi 100
'93 Eurovan
'82 Porsche 930

Reply #33October 13, 2008, 04:44:23 pm

Turbinepowered

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Converting a 1.9 head to instal on a 1.6 mech. block
« Reply #33 on: October 13, 2008, 04:44:23 pm »
I wonder how that protrusion affects flow in a ported head. Your shims and solid lifters might actually end up the better solution, so far as smoothness of flow goes.

Reply #34October 13, 2008, 08:34:58 pm

blkboostedtruck

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Converting a 1.9 head to instal on a 1.6 mech. block
« Reply #34 on: October 13, 2008, 08:34:58 pm »
is that your split window Karl?
Duane
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Reply #35October 14, 2008, 08:52:32 am

saurkraut

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Converting a 1.9 head to instal on a 1.6 mech. block
« Reply #35 on: October 14, 2008, 08:52:32 am »
Quote from: "Turbinepowered"
I wonder how that protrusion affects flow in a ported head. Your shims and solid lifters might actually end up the better solution, so far as smoothness of flow goes.


Yah, I know :(  And I'm really not happy about it.  But I'm up against the storage season.

I will end up as good as a ported head with the original valve guides.  But I know it could be better, and that BUGS me....

The problem that I didn't want to address is the over all geometery of the valves I'd end up running.

There are no valves that are a direct fit, head diameter wise, in a head modified to be a mechanical 1.9 head.

To use VR6 oversized TT exhaust valves as intake valves for the 1.9 head, they needed to be shortened allot to work .  The amount that had to be removed would have almost eliminated the top grove for the collets.  I could have lived with that.  But they were also 0.15mm smaller in head diameter.  So it becomes a trigonometery problem figureing how long the stem should be because they'd sit a little deeper in the head, and still end up in the adjustment range of the valve lash shims.

The 1.9 exhaust valve head diameter is also slightly bigger than the 1.6TD exhaste valve. so it has the same problem.

And I really want to try it out befor the snow (salt) starts flying.  So its the super long mechanical cam followers for now.

The right answer is custom made valves, and that is not out of the picture.  I'll probably go with thinner stems too.

No, the splitty is not mine.  But I wish.
'79 1.6TD RABBIT
'84 1.5TD RABBIT
'83 Diesel Westy
'86 Audi 5000 Turbo Quatro Wagon
92 Audi 100
'93 Eurovan
'82 Porsche 930

Reply #36October 16, 2008, 05:23:14 pm

saurkraut

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Converting a 1.9 head to instal on a 1.6 mech. block
« Reply #36 on: October 16, 2008, 05:23:14 pm »
The long mechanical cam followers are here:

'79 1.6TD RABBIT
'84 1.5TD RABBIT
'83 Diesel Westy
'86 Audi 5000 Turbo Quatro Wagon
92 Audi 100
'93 Eurovan
'82 Porsche 930

Reply #37October 16, 2008, 05:24:45 pm

zukgod1

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Converting a 1.9 head to instal on a 1.6 mech. block
« Reply #37 on: October 16, 2008, 05:24:45 pm »
Too Cool!!!
dan

99 Golf TDI (now CNG powered) , 82 TD Caddy

Reply #38October 20, 2008, 12:19:04 pm

saurkraut

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Converting a 1.9 head to instal on a 1.6 mech. block
« Reply #38 on: October 20, 2008, 12:19:04 pm »
Well, instead of wipping out my handy dandy 8mm drill bit and ream the guides that way, (I know it sound crude, but it has worked for me many times befor) I bought a 5/16" to 11/32" reamer from McMaster to do the job right:



Close up:




What I found is that guides reamed to the proper size feel looser than what I used to accept with the drill bit method.  Probably because the finish is more uniform.  I'm lucky that i didn't have a valve stick in the past.



I also double checked the possibility of drilling and tapping the top edge of the cam side to accept the earlier valve cover.  IT IS POSSIBLE.  But there is good news, and bad news.

I did crude checks in the past wit the G60 valve cover.  There are allot of stiffening webs in the top of it that interfered with the stud bosses on the 1.9 cam towers.  I dremeled out the interference points and low and behold, the stud holes in the corners line up, and they are also the right size for the tap!

So I drilled and tapped them all (No. 9 bit):



A DRILL PRESS IS MANDITORY.  If you get a crooked hole, the valve cover ain't going over the studs.

And there is pleanty of web thickness to almost cover the whole thread insertion:



Now the bad news:  The early steel valve covers won't work un modified:





The edge roll on the old steel cover interferes with the 1.9 straight gasket surface.

Allot of the edge roll has to be removed.  Here is the gasket in the valve cover showing how much over hang there is;



Its not out of the question, but it has to be reduced significantly, probably to 1/2 the gasket thicness.  I wonder what the right way to do this is?


The G60 valve cover, after a little dremel work, is a straight shot:



I also lapped all the valves.  So hopefully next week end, I'll have fire in the hole....
'79 1.6TD RABBIT
'84 1.5TD RABBIT
'83 Diesel Westy
'86 Audi 5000 Turbo Quatro Wagon
92 Audi 100
'93 Eurovan
'82 Porsche 930

Reply #39October 21, 2008, 07:02:47 pm

Smokey Eddy

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Converting a 1.9 head to instal on a 1.6 mech. block
« Reply #39 on: October 21, 2008, 07:02:47 pm »
awesome mate!
just perfect!
Can't wait to see it together.
Ed
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Reply #40October 24, 2008, 01:50:10 pm

Smokey Eddy

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Converting a 1.9 head to instal on a 1.6 mech. block
« Reply #40 on: October 24, 2008, 01:50:10 pm »
I wonder if i'd ever find a g40 or g60 cover at the junk yard...
if not im going to try flattening my 1.6td cover to fit with the aaz head and use all the mounting points for both styles
Ed
Blacked out mk2 AAZ Jetta RIP. You are missed.
White 1999.5 ALH Golf 2dr. Low & wide. Rammed off the road RIP.
Blue 2009 CR140 Jetta CBEA/CJAA. Malone stage 2. EGR/DPF/Exhaust-valve deletes. 2.5" open exhaust. ADP Turbo swap. 1-stage nitrous kit. THROWN ROD

Reply #41October 24, 2008, 03:19:34 pm

Smokey Eddy

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Converting a 1.9 head to instal on a 1.6 mech. block
« Reply #41 on: October 24, 2008, 03:19:34 pm »
Probably.
Ed
Blacked out mk2 AAZ Jetta RIP. You are missed.
White 1999.5 ALH Golf 2dr. Low & wide. Rammed off the road RIP.
Blue 2009 CR140 Jetta CBEA/CJAA. Malone stage 2. EGR/DPF/Exhaust-valve deletes. 2.5" open exhaust. ADP Turbo swap. 1-stage nitrous kit. THROWN ROD

Reply #42October 24, 2008, 06:24:47 pm

Smokey Eddy

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Converting a 1.9 head to instal on a 1.6 mech. block
« Reply #42 on: October 24, 2008, 06:24:47 pm »
Or use something much harder than the stock ones and just have tons of pressure on the middle points like you said.
Ed
Blacked out mk2 AAZ Jetta RIP. You are missed.
White 1999.5 ALH Golf 2dr. Low & wide. Rammed off the road RIP.
Blue 2009 CR140 Jetta CBEA/CJAA. Malone stage 2. EGR/DPF/Exhaust-valve deletes. 2.5" open exhaust. ADP Turbo swap. 1-stage nitrous kit. THROWN ROD

Reply #43October 24, 2008, 06:39:17 pm

MJF

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Converting a 1.9 head to instal on a 1.6 mech. block
« Reply #43 on: October 24, 2008, 06:39:17 pm »
Did I miss something, but why not 1,9 valve cover?
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Reply #44October 24, 2008, 06:39:56 pm

Smokey Eddy

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Converting a 1.9 head to instal on a 1.6 mech. block
« Reply #44 on: October 24, 2008, 06:39:56 pm »
no funds  :roll:
Ed
Blacked out mk2 AAZ Jetta RIP. You are missed.
White 1999.5 ALH Golf 2dr. Low & wide. Rammed off the road RIP.
Blue 2009 CR140 Jetta CBEA/CJAA. Malone stage 2. EGR/DPF/Exhaust-valve deletes. 2.5" open exhaust. ADP Turbo swap. 1-stage nitrous kit. THROWN ROD

 

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