Engine Specific Info and Questions > Diesel Swaps

? 1.9TD block w/ 1.6TD heads ?

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mstephenson:
Hello Everyone,

I hope I didn't mess up. I went and looked at a car I didn't need or particularly want. And yes, I bought it. A MK2 Golf. The ad said 1.9 tdi. I didn't know what I was looking at since the only engine/s I studied was/were MK1 1.5na and 1.6na.

So, the son said the father (deceased 2001) ordered the block from California from a Passat. He said it was an ALH block. It looks like some kind of similar conversion of what is being sold on eBay (http://www.ebay.com/itm/VW-Volkswagen-1-9D-LONG-BLOCK-ENGINE-with-1-5-1-6-to-1-9-UPGRADE-KIT-/171529128211). Eventually, I was told it was a 1.9 block (confirmed the block stamp is really a 1.9D not TD) with the original 1.6TD head and components bolted on including some modifications. Assuming this is true, then I have questions:

--What is this block? Block stamp 1.9D below exhaust and this is the number from below #3 and #4 (20J93). If this is enough to ID, is there a database to resource?







—Motor observations. The block should have <40Kmiles on it while the head and other transferables will have something around 125Kmiles. The motor seems tight after 3000rpm. The turbo is barely audible. No obvious whistling or spooling sound, but it’s there for sure. Sweet spot is 3000rpm (~65mph) in 4th. Does that sound about right?

--Is this setup ok? and reliable? I want to drive 90 miles a day, every day; nothing fancy; good mpg (+40), and not get run over.

--Oil capacity. What should I know? It has an oil cooler. Does it need a deeper pan if it is the original 1.6 pan? Frankly, I have no idea if this matters. I read 4.5l (4.8Q) for 1.9TDI?

--Injection pump. What is this? 1.6 or 1.9 pump? and does it matter? The son said the father took it to a diesel shop (not a VW shop) to do something about it starving fuel to motor.



—Turbo. How/Where to ID the turbo?

--Transmission. The numbers were scratched off. Does this matter? Also, the speedo cable looks like this on the tranny end and the other end is some kind of sensor sensing a magnet epoxied to the axle. Do I need to put a legit cable back in?



The water temp gauge hardly moves. I plan on putting a mechanical gauge shortly. That terrifies me.

What are some observable differences between the 1.6D and 1.9D. Can you recommend some specific items I need to read up on to be a responsible TD owner/operator?

That's all I can think of at this moment. I am sure I am not done questioning the purchase or my sanity. Thank you everyone.


Michele

libbydiesel:
None of your pics show the block code.  The block code is not part of the casting.  It is stamped INTO the machined surface shown here: 

It is not a TDI.  It is definitely NOT an ALH block.  It is probably a 1Y.

The head is *not* a 1.6 head.  It is a 1.9 head.

Best way to identify what turbo it has is to take a picture of it and post it up here.

It should be reliable engine if maintained well. 

vanbcguy:
Looks like an AAZ to me - block code will tell for sure. Appears to be a reasonably well done installation too, nothing sticks out at me as being really off. The intake appears to be a factory AAZ piece, that's definitely a 1.9 IDI head, etc. My guess is its a totally complete AAZ, which is an IDI turbo diesel.

They're fine engines - looks like it has been set up to use the v-belt accessories from the 1.6 which is good, that actually solves one of the weaknesses of the 1.9 engines in their stock form (they had an issue with the crank nose caused by the switch to a serpentine belt and a heavier more powerful alternator).

Oil volume will be the same as for a 1.6. The engines are extremely similar. Use a good quality diesel rated xW40 oil - if it isn't leaking or burning it then a synthetic like Rotella T6 5w40 would be a great choice. If it's using oil then Rotella T 15w40 (the non synthetic cheaper one) will be fine.

Injection pump appears correct for an IDI diesel. Looks to be in good shape too.

I think you did well!

Bryn

Sent from my XT1097 using Tapatalk

libbydiesel:
My guess is 1Y as opposed to AAZ because he mentioned the block says 1.9D instead of 1.9TD on the back of it.  I'll be curious to find out the block code.

mstephenson:
Block backside:



Is there a napkin zip-tied around that leaky glob of mess?



Turbo: GarrettT3 from what I gathered from the numbers below and a post here from ten years ago. Is this a good mate to motor?





Engine Code: Brass toothbrush and brake cleaner produced this bunch of nothing. I am going to try and polish with either 600 sandpaper and/or brush fitting for dremel. Any sure fire suggestions will be applied.



Oil has been changed to the Rotella T6 synthetic and gear box is next along with radiator (coolant test showed poorly).

Michele

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