hi im new

[jimbobpolo]

hey guys im new on here, i have a 1997 polo 6n 1.9d that im thinking of doing a td conversion on and im looking for some help,
i have a complete 1.6 gtd JR engine and a somewhat imcomplete 1.9 tdi 1Z engine (and also the original 1.9d AEF in the polo!)

im very tempted to use the JR engine and 1Z gearbox/clutch/flywheel combo as ive read alot on the US forums that the JR engine is the way to go for decent power?

i only paid £50 for the tdi 1Z bits so im not too worried if i dont use them, but would be nice to get it all up and running if its worth it?
any help/opinions would be much apreciated!

cheers then
james

[burn_your_money]

Welcome aboard James.

I've never seen a polo or the AEF, from what I know you should have enough parts to build either the 1.9 as a turbo, or swap in the 1.6 turbo. The 1.6 is more rev happy then the 1.9 but the 1.9 will have more low down torque.

What kind of car do you want to have?

[jimbobpolo]

im missing a few important bits from the 1.9 1Z tdi set up such as, IP, wiring loom, ecu and injectors so i think i may go with the 1.6 JR
im after a torquey setup as i use the car for mainly short journeys to work and back and the occasional long trip.

my 1.6 JR has the KKK k24? fitted and looks huge compared to the garrett t15 that is on the 1.9 1Z!
also ive noticed there is a massive difference in the inlet manifolds,
should i be using the inlet and exhaust manifold and turbo from the 1.9?
i think it might give better spool-up than the KKK?
what are peoples thoughts on this?

i will post up some pictures of the car and engines and parts i have

im thinking of doing a build thread on my project if people would like to see what im up to?

cheers then

james

[catlin_cava]

Welcome to the club sounds like a pretty cool project your doing, and build threads are always a good thing because it does  help others on their projects

[aidan]

the 1z gt15 is good for about 140bhp (on the 1z), maybe a little less on the 1.6
Your not likely to get more than than that on a 1.6, so i'd use that. Downpipe may need to be bodged to fit though.
Any tdi inlet manifold is rubbish really, depending on your intercooler setup, use an 8v gti/G60 manifold (or the existing 1.9d manifold if keeping the 1.9) as these are cheap.

My choice would be keep 1.9 engine, fit 1z turbo, gtd injectors or equivalent, JR pump modified as in the FAQ section.

If/When the clutch goes, then think about the 02a gearbox (from the 1Z), but its not a straight swap, need to swap the shifter in and the ibiza clutch cable adaptorhttp://www.clubgti.com/forum/showthread.php?t=107068&highlight=ibiza+clutch+cable

[jimbobpolo]

i think ill be using the gt15 for the time being, and keep the k24 as an upgrade so to speak.
i have a bmw 525 intercooler that ill be front mounting (my car does not hav AC!) so im pretty confident i wont have any high charge temp problems
i have all the exhaust downpipe setups from the JR and 1Z so i can use whichever one fits hopefully!

i do have a g60 inlet manifold but im unsure if it will fit height-wise, as the bonnet on my polo is pretty tight fitting!

i only have the 02a gearbox (like a muppet i sold the 4+E gearbox i had on the JR to a friend that wanted it for his caddy) but i do already have the cable change shifter assembly from a mk3 golf and the Seat clutch cable adapter!

ill start a build thread off as ive just recieved all the gaskets, timing belt etc! time to get cracking!

[aidan]

the stock 1.9d manifold will be just as good as the g60 and already has the D ports.
I don't rate the 020 boxes anyway, the rod change is nice, but 2nd gear crunch and the short ratios aren't. Have a look into the 02j shifter for the 02a box before fitting, the 02a shift really spoils it to be fair.

[rolo]

Which engine are you going for?

[jimbobpolo]

im going with the 1.6td JR engine for the time being,

my polo 6n already has cable gearchange linkage, but the cables are too short for the 02a 

ive decided to pull the sump off the engine to check the condition of the bottom end, any things i should be looking out for??

[macka]

well if you have the cable set up already, swapping in a proper length cable will be childs play.

[jimbobpolo]

right, a spanner in the works!

took the head off the JR to find no less than 6 cracks in it! 

not sure what to do now, i have engines in bits all over my garage now!
should i be thinking about turboing my 1.9d n/a engine or making a hybrid out of the 3 engine i have?

help!

james

[aidan]

turbo the 1.9, people who have had them apart say they've got the oil squirters anyway so just as good as the jr, I wouldn't have even considered putting the 1.6 in, especially as the 1.9 is already fitted and running.

[jimbobpolo]

i dont think it will be as easy as that, then 1.9d n/a has a few issues, uses lucas injection and im not sure if the td injectors would fit? plus it only has a 175mm clutch with an 085 type gearbox that jumps out of gear regularly which is why i was planning on putting in the 1z engine and gearbox, the 1.6 JR seems a much more attractive option, ill post some pics of the AEF in my polo and see what people think

james

[macka]

well then swap out the tranny. Score a bosche pump and injectors, fit them up....easy peasy 

[jimbobpolo]

i already have the 1.6gtd bosch IP and injectors, will they do the job? i can swap the gearbox over, but do you know if the flywheel will fit the 1.9d n/a engine?

james