1.6TD bad need help finding right 1.9TDI

[mtnsammy]

I have blown yet another 1.6TD. This time a fan relay gave way at 65MPH and 15 minutes later in the desert the head cracked. 22 gallons of water to get it home. The motor runs but in 15 minutes the overflow tank bubbles like a hot tub. This is the 5th time. Motor is 50 over and has been re machined 3 times. The heads have been cut/ welded 5 times. I live in the Inland Empire outside of San Bernardino California. Not many shops know how to work on this motor. They tend to weld shut oil ports and water jackets. I have not tried any LA California shops yet. Quality German in Montclair is not acceptable for motors or work. Poor standards.

I am tired of hard to find parts and limited supplies. I was thinking of a newer TDI but I have read the electrical can be difficult. No longer am I trying to get 700 HP out of the motor, I just want the 35MPG and a motor that runs.

The AAZ is a common trade but there are none in wrecking yards only expensive machine shops. My 1.6 runs and can be used for parts and adapters if needed. Is it hard to adapt the 2000-2008 TDI motors?How many car donor parts other than the motor do I need?

I am just looking for suggestions of which motor and how hard it is to adapt. I may even be re-wiring the rig too with a metal dash. Using the entire motor and dash may be a possibility. If you have a thread of your own exchange I would love to read several threads that were successful. I am not finding any good results with the search feature.

[the caveman]

find an earlt TDI an IZ or AHU[ 98-99.5 jetta] and get a mechanical TDI pump built up. easy peasy

[blkboostedtruck]

I did not realize your from my home state ! i grew up in Bellflower, near Long Beach ! 605 & 91 freeway intersect!
i been a trans plant here in wisconsin since "94
all my family is still out there! have a sister in Ontario and more relatives inland in San Diago! Jamul to be exact!

anyways what body are you using? you never mentioned that!
AAZ would be the easist to put back in place of that 1.6TD
i have an AAZ in my caddy and much better power over  the 1.6TD i had in before! 68HP vs. 80HP i love it!
i work nites but you can call me between 12pm and 4pm at
414-840-1395
i have no way to ship at the moment because of not working for a company that i can have access to banding and pallets and etc.
Duane

[mtnsammy]

I am running an 86 Samurai with stock axles and trans bolted up with an Acme adapter, I am thinking of going to the Toyota Trans and axles with this swap.  So far this has been a lot of fun but the costs are real high when the head blows. Manual pumps are OK but at 1200 my wife needs some real convincing. I have found Prothe and Jiles but no one else. Some say I can bolt my 1.6 brackets to the front and reuse the IP I have?? If this is true I can go with a longblock and run in less then a week.

BTW I am in Big Bear right above Ontario/ San Bernardino.

[mtnsammy]

So any word on using the brackets off a 1.6 on a 1.9?

How hard is it to wire up the TDI with the TDI IP?

[jackbombay]

There really aren't that many wires to deal with, the yahoo group for TDI vanagon swaps has some good info on the wiring.