Swapping 1.9L and 1.6L cranks?

[mac.man25]

So,

I have a spare 1.6L laying around and was considering building it into a little more powerful engine for commuting and a little fun.  

I was wondering what I have to take into account in order to fit the 1.9L crank into this engine.  At the moment i was thinking of replacing just the crank, but the longer stroke would create problems with protrusion, what else do I need to change to get everything to fit?

I would like to keep the same bore, so I would like to keep the same pistons, but I don't know if that would be possible.

[Rabbit on Roids]

probably gonna have to spend alot on custom parts. i can just about guarantee that you wont be able to bolt some oem vw parts together and make a stroker diesel out of a 1.9 crank and 1.6 pistons. i know they made a 1.7d that had a 1.9 bore and a 1.6 stroke (someone chime in with a correction) but that was an industrial engine.

[jtanguay]

to help with protrusion you could get a plate machined to go in between.  sealing between the plate and the block will probably be difficult though.  and it will have to be seamlessly honed.  probably more trouble than its worth though.

[truckinwagen]

I am looking at running 1.9 rods and pistons on a 1.6 crank in a 1.6 block.

I am going to have the block sleeved and have the sleeve protrude out of the deck, then I am going to make a copper deck spacer to bring the rest of the deck up to the top of the sleeve.

I am also going to custom make a copper head gasket and use ARP studs to allow for lots of clamping force.

I am not sure how well it will work out, but there is only one way to find out!

-Owen

[Rabbit on Roids]

i wonder how much you would have to shave the deck of a AAZ block? or a 1.7 block? didnt those have 1.6 cranks and 1.9 bore size? i just dont really like the idea of making a spacer for the head, as its gonna be a royal *** to time and get timing belts for. but if everything works out good, i just might have to do this also. dunno though, i just like the short stroke/long rod engines better.

[truckinwagen]

yeah, I like the longer rods better too, much better dwell for higher rpm running.

the problem is that getting any block at all is a real pain up here, let alone an AAZ or industrial one.

I have a motor in my car to run while I play with this one.

as for timing belts I think I will run the AAZ one and if I need to I will move the mounting stud on the head a bit.

[mac.man25]

Wow, such awesome answers.  Thanks guys.

So I know that the 1.6L and 1.9 use different rod lengths (I believe the 1.9L being longer)  but if the 1.9 has a longer stroke, how can it have both longer rods and a longer stroke?

Do they fit this with a taller block?  Or what?  Unfortunately I don't have a 1.9L diesel block laying around for me to play with.

Now here's an even crazier idea, using a gasser block with a diesel head?  is it possible, is it worth it?

I've been looking at this site, and it lists out a LOT of numbers  about the mk2 era gassers.  Is this possible?  I'm ok with dropping a little compression ratio from the original 23.0:1  

I've also been using [urlhttp://a2resource.com/eandt/allengines.html]A2 Resource[/url] for some other information too, though I have found a couple errors.

[Rabbit on Roids]

you can use a 1.6 gasser block. they are not nearly as tough of a block though. but you could take a diesel crank and block, put gasser stuff in it, a gasser heron head, and throw some nitrous at it. :twisted:

as for making some gas/diesel hybrid motor.. good luck. if there were any sort of gas blocks with benefits over a diesel block, im sure there would be more info available. and yes.. an AAZ block was taller than a 1.5 or 1.6 block.

[hamradio]

Couldn't one take a 1.6 diesel head and put it on a 1.6 gasser block, and avoid using the heron head?

[Rabbit on Roids]

no, i said to take a diesel block and crank, put gas rods and pistons, and use a strong gas head. make a bullet proof gas engine that can handle a ton of nitrous. i know a guy that built an engine similar to the one i described. it had ok power, until he touched the button, then it had bunches  :twisted: