Wiring/mounting differences for MK1 1.6 N/A -> MK3 1.9T ?

[Pre95]

So once my move is completed (roughly a month from now) I will be starting out sourcing all the parts needed to swap in a 1.9T & 5 speed M/T from an MK3 in to my MK1 1.6 n/a 4 speed m/t  . Figured I had better get a head start on getting my list together for what parts will be needed, and what kind of wiring changes will have to be made.

Any insight is greatly appreciated, I will be going through forum searches as well to nail down as much of the pertinent information as I will need.

[bert]

i did this,a mk1 golf diesel 1.6 na to mk3 td aaz mk3 engine and box,went well,not a complex job,you need the engine mounting from the 1.6 though,the wiring was the same for both for me,ive got a pump with no electronics so there 







Bert

[Pre95]

That's exactly what I was hoping for, straight forward without wiring changes. AAZ you say? I know there is a newer version of the 1.9(TDI motor), what engine codes am I looking for on the swap, only the AAZ? Just want to make sure I don't get them mixed up when sourcing parts or advise.

[rabbitman]

Bert

I just noticed your clutch and speedo cables go into the right side
Never seen one like that, how does your brake booster work being on the left though? Nice job

[burn_your_money]

If you want the 1.9l engine then get the AAZ motor. Fix the crank pulley before you put any time or money into it though.

As for wiring pretty much everything is the same. Swap the mk1 coolant flanges and sensors onto the 1.9. You will need to do some custom wiring for the reverse lights.

Also, make sure you get an AAZ with a pump that has a single piece pump pulley. You'll run into problems with the passenger side motor mount if you get the pump with the 2 piece pulley.

[Pre95]

Very good stuff to know! Now the questions start...

1) The crank pulley needing to be fixed, whats the problem with the stockers? I am guessing there is a recalled piece or an aftermarket solution?

2) Would I be able to use the 1 piece pulley from the pump off the 1.6? I have only seen the 1.9T in pictures but the pump seems quite similar (though I know internally the turbo motors IP is different)

3) Does the MK3 5 speed transmissions used with the 1.9T have 100mm or 90mm output flanges?

Thanks for all of the info guys!

[burn_your_money]

I didn't see this picture when I posted
http://i78.photobucket.com/albums/j95/citigolf_2006/Image002-2.jpg
Looking at the bracket mod it looks like either pump will work.

Search for crank gear fix or something along those lines and you'll get the idea

MK3 trannys are 100mm

[Pre95]

I didn't see this picture when I posted
http://i78.photobucket.com/albums/j95/citigolf_2006/Image002-2.jpg
Looking at the bracket mod it looks like either pump will work.

Search for crank gear fix or something along those lines and you'll get the idea

MK3 trannys are 100mm

Ok so with 100mm output flanges would I need the front half shafts from the MK3 as well, or would I swap the 90mm flanges from the stock 4 speed over to the new trans?

And I am un-sure what "bracket mod" I am looking for in the pic. Do you mean the IP bracket? I am planning on a Giles performance pump for the newer motor before install, so suggestions on which pump to source for rebuild would also be helpful.

I will check in to the crank pulley fix as the time gets closer. Still need to source a motor & trans as well... Anyone crash there MK3 lately?

[jack's lack]

I'm going to be performing this swap very shortly I'm going to pick my AAZ up from the shipper tomorrow. I am planning on doing a build thread and I have asked a lot of the same questions to these guys in recent history. So maybe we can be a resource to one another.

The crank pulley on the stock AAZ is really an Achilles heel. it is held in by a fragile keyway or notch and if the bolt works loose and the pulley is allowed to move at all it will shear the key and tear up the keyway, which means new crank at best and if the timing slipped substantially your pistons will likely meet your valves in an unfriendly kind of way; which will = $$$$. I am told this it is inevitable if you plan to make any real power with these engines.

I have found 3 solutions for this (others will correct me if there are more)

1. beef up the stock pulley crank connection with some dowels. there is a good thread on this so search
2. have the stock crank end milled to the "D"-shape used by later TDI engines and use their pulleys
3. replace the entire crank and pulleys with one from an early MKIII TDI (1Z and AHU) engine codes these do not have the oil pump drive gear and will bolt up. 

In all cases it is advisable to switch the alternator pulley to the later "freewheel" type used on the TDI engines (the AAZ has a serpentine belt setup FYI. I am told you could also switch it to a V-belt and avoid this issue as well). The rotational inertia of the alternator wreaks havoc on the joint in question when your high compression ratio diesel brakes and the alternator "wants" to keep spinning, the TDI alt pulley allows this to happen just the way you would coast on a freewheel bicycle. You can easily find this pulley for about $60 new at your favorite internet VW parts store

As has been mentioned there is a ton of info on this in the search. I have been reading it for weeks in preparation for doing this.
I am hopeful this is helpfull

[burn_your_money]

Ok so with 100mm output flanges would I need the front half shafts from the MK3 as well, or would I swap the 90mm flanges from the stock 4 speed over to the new trans?

And I am un-sure what "bracket mod" I am looking for in the pic. Do you mean the IP bracket? I am planning on a Giles performance pump for the newer motor before install, so suggestions on which pump to source for rebuild would also be helpful.

I will check in to the crank pulley fix as the time gets closer. Still need to source a motor & trans as well... Anyone crash there MK3 lately?

Get mk1 100mm axles. I don't thinkthe 4 speed flanges will go on the mk3 tranny. Mk3 axles are longer then the mk1 ones.

Yeha the bracket mod is the IP mount/passanger side motor mount. You are loosing some support by doing that. Whether or not it's important though is another story.

Get a pump with the 50mm mount from a car without AC (mechanical fast idle). You could call Giles and ask him if he has any suggestions as well.

I have several AAZ engines right now. Only one runner though. We are pretty far away from each other though.